550 Zephyr 1991 B2 UK bike recommission after stored a few y

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Richard
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Joined: 24 Aug 2017, 14:35
Location: Zeewolde NL
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Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by Richard »

Progress is going on strong I see, looks really good. As so looks your other bike b.t.w. ;)
linuxrob
Posts: 27
Joined: 25 Mar 2023, 17:14

Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by linuxrob »

Good thought, will do some research into those spring, may Hagon can supply some to fit those shock, i really like the look of them and the damping still works.

done some more today, back brake caliper and master cylinder rebuilt and fitted with new Venhil line. Rear wheel and swing arm in and torqued up.
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156_7422.JPG
linuxrob
Posts: 27
Joined: 25 Mar 2023, 17:14

Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by linuxrob »

Almost ready for MOT, just the tank to fill with fresh fuel and once over.
nearly done 8th dec 23-2.jpg
nearly done 8th dec 23.jpg
Stereordinary
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Joined: 05 Aug 2020, 16:21
Location: Vancouver Washington USA
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Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by Stereordinary »

Looking really nice! I'm a little jealous that yours has the bullet turn signals and gauges. Wish mine did.
A breeze from the west.
linuxrob
Posts: 27
Joined: 25 Mar 2023, 17:14

Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by linuxrob »

I always wondered why the US market had those instruments (clocks) fitted when the bikes were "retro".

Finished a full clean of the tank and petrol cock. will be putting some fresh E5 in today drained from the GS125.
linuxrob
Posts: 27
Joined: 25 Mar 2023, 17:14

Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by linuxrob »

Feb 24 update:

bit of cleaning and got a rack and topbox plus small screen on marketplace for £50. fitted and all checked over for the MOT i hope this week.
156_7582.JPG
Stereordinary
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Joined: 05 Aug 2020, 16:21
Location: Vancouver Washington USA
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Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by Stereordinary »

Very well done!
A breeze from the west.
linuxrob
Posts: 27
Joined: 25 Mar 2023, 17:14

Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by linuxrob »

MOT last Friday in the rain unfortunately, now taxed and ready to use for work.
mot day 1-3-24.JPG
linuxrob
Posts: 27
Joined: 25 Mar 2023, 17:14

Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by linuxrob »

Completed the first week of bike use, just over 120 miles, gunned it a bit today and clutch slipping after 7000 rpm, new plates, springs and gasket ordered. will fit next week (Friday) will do the oil filter again as well as change oil. There is a guy here in the UK (Brian from Hexham ) who does teh clutch damper rubbers, will get in touch and see if he can do the Zephyr clutch as well as my spare Z500 basket as they all should b hard and need replacing by now.

watch this space.
linuxrob
Posts: 27
Joined: 25 Mar 2023, 17:14

Re: 550 Zephyr 1991 B2 UK bike recommission after stored a few y

Post by linuxrob »

Clutch off and noticed the thicker plain plate had been fitted as the LAST plain plate as opposed to being the FIRST plain plate as per the manual.
plain plate in wrong.JPG
clutch basket and my 2 spare Z500 baskets with Brian for damper rubber replacement, ordered new release bearing (6001) and needle roller (std bearing from eBay) and a genuine bush together with a new retaining nut.

Looked into the starter prob, sometimes relay would just click, if bike moved backward in gear a bit then the starter would turn again. symptom of worm brushes or bad commutator. Took the easy route when i got the starter off and ordered a starter repair kit for around £20.00, i could have got a used motor for under £30.00 but may have the same issues.

just stripped the motor cleaned it out, cleaned the commutator (no wear at all!!) fitted the brush and holder kit reoiled the bush and rear bearings and refitted.
one brush worn-brushgear.JPG
commutator cleaned.JPG
clutches should be done after next week.
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