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  #1  
Old 16-11-2017, 11:14 PM
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Default Zr1100

So much for getting it up and running this year
I had a matter to resolve with the local authority who are about as helpful as dead things. Slapped me with a bill for 2300 and then refused to answer my letters, emails and voicemails. I'm still raging inside.
Bill was canceled and I had loads of profuse apologies...... but no resolution.

Anyway enough of that b*****s, here's the new shocks.
I increased the length by 4cm over standard.
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Old 16-11-2017, 11:27 PM
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Front forks rebuilt and using Wilber progressive heavy duty springs.
Just about got away with machine polishing the tubes.
Work was done by Revs Racing in Halesowen, just off the M5.
Nick and John run it and are a very decent guys.
A quality job!!
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Old 16-11-2017, 11:36 PM
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The spension was very worn out on this bike.
The front forks had 2.5cm of sag with the bike just on its sidestand.
Probably 5cm when my bulk was sat on it.
Nick at Revs put one fork leg on the ground and just pushed it up and down stop to stop easily with one hand. Yeah it was clapped out
With the replacement 4 into 1 exhaust sorted (apart from one short stud, but Ive got a fix for that in hand, will show you later) the ground clearance is more important because of the large size of the 4 into 1 collector pipe underneath the motor.

That's summat to watch out for when you see these lovely old classics for sale on their original suspension, because they will need replacing/rebuilding and it ain't cheap. A good set of prog springs for the front will set you back about 125 then there's polishing or rechroming the tubes.
The fork seals and others fork bits aren't too much, but it all adds up.
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Old 17-11-2017, 04:22 AM
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Wotcha Matey! Wondered where you'd got too. See you've been busy then...
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Old 17-11-2017, 07:35 PM
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Ello mate, yes I've been buried in the garage.
A 35 item list of things to do is down to 8.
I just focused on the bike and left other things be for a while. I have done shed loads on the bike.
I've done other stuff which wasn't even on the list.
Its never going to be a concourse job and I didn't intend it that way. A couple of my mates have been badgering me to get it done!!

The forum has picked up a bit?
Hows the home restoration been going?
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Old 17-11-2017, 07:41 PM
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I had been over on MCN forums for a few years since they invited us back. But the bastards have banned all of the regular posters which is no small number. No one knows why we have been banned. No one can register and one ex member said mcn said they were closing it down.
It doesn't take several weeks to shut it down.
Had some good peeps on there and old school bikers.
I am not amused.
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Old 18-11-2017, 04:36 AM
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Home restoration are on a home straight now...I think! The forum seems to have gone really quiet. Down to about half a dozen od us die hards! We need some new blood! Maybe you could persuade some of those MCN bods over here?

Polishing the legs isn't too difficult. I used to be a buyer for a marine window makers and they had three polishing shops. I used to buy from Lea Manufacturing, then they got too expensive and we endied up going to Lippert-Unipol. The art is know what type of mop to use on what type of metal, and the grade of polishing compound to use. I've got a load of stuff in my workshop, but it doesn't make me any better a polisher! But I can get by quite well when I have to.
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Old 18-11-2017, 04:02 PM
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Home restoration are on a home straight now...I think! The forum seems to have gone really quiet. Down to about half a dozen od us die hards! We need some new blood! Maybe you could persuade some of those MCN bods over here?

Polishing the legs isn't too difficult. I used to be a buyer for a marine window makers and they had three polishing shops. I used to buy from Lea Manufacturing, then they got too expensive and we endied up going to Lippert-Unipol. The art is know what type of mop to use on what type of metal, and the grade of polishing compound to use. I've got a load of stuff in my workshop, but it doesn't make me any better a polisher! But I can get by quite well when I have to.
I cant invite anyone over Friar because I can't login and no one else who was banned can either. I don't know what they are playing at tbh, there were some very decent people who have never said a bad word who've been banned. The forum wasn't doing well tbh.
What I don't understand is why so many regular posters were just banned and yet the spammers who are posting stolen bank and card details all over the forum are still doing that. Makes no sense.
Anyway that one's closed. Dead.

Well I'm glad to hear your getting ontop of it with the house.

Polishing the tubes was by far the cheaper option. To have them re-chromed through Revs would have cost another 160 Ooocha !
So thank F mine were ok with just a polish.
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Old 18-11-2017, 04:15 PM
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After finding a machinist who could mill the collars down so they would fit the new pipe flanges, I was able to paint em and refit them on the bike.
That left the shorter stud on the left hand outside to try out, but even with reducing the collar depth I could still only wind that one flanged nut on by 3 or 4 threads,
about 1/2 of the nut which imho isn't enough in that location.

After racking my brains for a long time...... hard to find em innit.
I came up with a decent fix.
By fitting a stainless steel captive sleeved nut. The end is an allen key fitment.
I bought a few off ebay to see what would best do the job seeing as they were only 4 to 5 each.
With a couple of stainless washers on and the holes drilled out to 12mm then it should be good to go.
Photo shows the two milled collars and two flange nuts with the stainless steel sleeved nut.
Obviously the flanged nut will not be fitted on the short stud. Its going to look a little odd, but I can live with that as long as its structurally sound.
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Old 19-11-2017, 02:58 AM
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Any chance of a photo of the stud in question? perhaps a fresh bod looking at tit might come up with something?
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Old 19-11-2017, 11:29 AM
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Any chance of a photo of the stud in question? perhaps a fresh bod looking at tit might come up with something?
I quite often come up with some thing looking at tit
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Old 20-11-2017, 05:38 AM
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Lol!...I often look a tit! This being one of 'em!
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Old 25-11-2017, 10:57 PM
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Any chance of a photo of the stud in question? perhaps a fresh bod looking at tit might come up with something?
Will do and we will see if anyone has any other ideas.
But there is no way I am going to replace that stud.
The monkey metal they used in these bikes is legendary as anyone who had bikes in the 70s and 80s will know.
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Old 25-11-2017, 11:04 PM
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The unburned fuel scavenging system is cack and for what difference it makes on the bikes fuel economy or emissions, it had to come off. Not an uncommon modification.

Reed valves on a 4 stroke? No these are the pressure dependent ports to release exhaust fumes back into the induction system at the air filter housing.
Blanking plates made by moi.... set in black VHT silicone adhesive.
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Old 25-11-2017, 11:06 PM
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Fuel tap service kit....
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Old 25-11-2017, 11:10 PM
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Tank de-rusting jollop.
You know caustic soda? Don't spill even a tiny bit on you
Surprisingly there was virtually no rust visible from any orifice, but I still did the deruster.
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Old 25-11-2017, 11:27 PM
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Sanctuary are a well known custom bike builder in Japan and this is one of their ZR1100's. Mine is nothing like this!
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Old 26-11-2017, 11:23 AM
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Quote:
Originally Posted by HOS View Post
The unburned fuel scavenging system is cack and for what difference it makes on the bikes fuel economy or emissions, it had to come off. Not an uncommon modification.

Reed valves on a 4 stroke? No these are the pressure dependent ports to release exhaust fumes back into the induction system at the air filter housing.
Blanking plates made by moi.... set in black VHT silicone adhesive.
Had no idea they where running EGR valves on those bikes back then, though it was limited to cars, but my experience of Jap bikes back then is limited to Z650/Z900 and Yamaha 650.
looking forward to seeing pics when its finished.
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Old 27-11-2017, 08:03 PM
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Had no idea they where running EGR valves on those bikes back then, though it was limited to cars, but my experience of Jap bikes back then is limited to Z650/Z900 and Yamaha 650.
looking forward to seeing pics when its finished.
The ZR1100 or Zephyr 1100 was made between 1990 and 1996 or there abouts. Literally the very last of the air-cooled bikes. No slouch either they punt out 95bhp as standard. The models went A1, A2, A3, A4, A5, B6 and then C models.
The B model was the last one and had wire wheels and different front brake calipers. The C model isn't a Zephyr, it's a totally different bike, the water-cooled ZRX 1100 which shares no parts with the Zeph. I see a lot of sellers on ebay selling parts for Zephyrs which are in fact for the C model which isn't a Zephyr.

The originals 1970s classics are silly money now especially the old Z900. All good bikes included the z650 and xs650. I would still like an xs1100 which hasn't been messed with or a cbx1000.

Thanks for the pos feedback I will post some more photos and when I wheel it out of the garage for its first daylight in 6 years. I'm hoping it won't be too long now.
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Old 27-11-2017, 08:08 PM
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The big rapid Zzr1100D had the same crappy unburned fuel recovery system and a few other ujm's of that time.
Ive had a ZZR1100, a GPZ1100 A fuel injection and a GPZ1000RX. Crazy fast bikes in their day.
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Old 28-11-2017, 04:25 AM
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Still no slouch now if set up nicely and kept fairly standard.
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Old 28-11-2017, 12:43 PM
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Sanctuary are a well known custom bike builder in Japan and this is one of their ZR1100's. Mine is nothing like this!
That's just bloody lovely that.
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Old 29-11-2017, 09:33 AM
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That's just bloody lovely that.
Its nice innit

I keep looking on the WeBike parts site in Japan which is in English.
Its like an Aladdin's cave of top spec performance parts.
Even for my Zeph there are maybe 50 different exhausts to choose from.
Some are 3 or 4 grand
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Old 29-11-2017, 09:36 AM
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Still no slouch now if set up nicely and kept fairly standard.
That's the general idea to keep it fairly standard but just replace most things with better quality parts. I've been shaving weight off the bike, removing the unnecessary stuff. But I need to shave some weight off me next.
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Old 29-11-2017, 09:41 AM
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Another little job "we" have done
My little lady applied the new lettering prior to me satin clear coating the switch gear casings.
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Old 29-11-2017, 09:50 AM
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Carbs are fully rebuilt and cleaned with new gaskets and O-rings, also a hybrid Stage 1 dynojet kit. The stock air-box is gone and replaced by custom designed PiperX pod filters. The standard air-box between the air filter housing and the carbs is a total b*****d to get in or out. The old air filter housing is now an underseat storage bin.

I got a billet fork brace which looks like titanium.
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Old 29-11-2017, 10:03 AM
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While I was in a bike parts shop in Cov, in the "bargains bin" I found a steering damper for the old Z900 which had no instructions in a battered box for 19 so I bought it to see if it would fit. Nothing ventured and all that

When I first offered it up on the bike I thought yeah, maybe I've got a chance to make it fit. There is only one place the bracket could be fixed to the bike.
I won a right sized billet fork clamp on ebay for a tenner.
After much thought and offering it up I went for the bracket build.
I measured and remeasured the location on the bike and used cardboard to get the shape right. The bracket would have to be bent as well.
So I used 4mm aluminium plate and cut it and bent it using plenty of heat.
It went summat like this.....
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Old 29-11-2017, 10:05 AM
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The finished item and the bars turn lock to lock without any problems.
A matter of good measurement and some good luck !
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Old 30-11-2017, 05:37 AM
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That's the general idea to keep it fairly standard but just replace most things with better quality parts. I've been shaving weight off the bike, removing the unnecessary stuff. But I need to shave some weight off me next.
I'm on the same target! I've lost 10lb so far! just another 4 stone or so to go!
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Old 30-11-2017, 10:54 AM
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I'm on the same target! I've lost 10lb so far! just another 4 stone or so to go!
I have got to have a go soon. No good shaving all that weight off the bike when I'm carrying a large excess. My ideal weight when I was strong and fit was 18 stone. I'm carrying a few more since my accident.
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