Z650 / GPz engined Restomod

With the engine cases back from being ceramically coated, loosely put them together to see how they look. Cases are empty of course, though I have lapped and refitted the valves. The original alloy plugs on the end of the oil galleries of the head have been removed, to make sure the galleries were clear of any blasting grit, then replaced, the larger ones with new alloy plugs and the smaller with stainless 8mm grub screws.

Your engine looks nice.

And solid call on removing the oil galley plugs for a proper clean out.  

Despite the engine not having been run since 2000, it was in good condition with little apparent wear, except for one thing.. the splines on the output shaft were badly worn. The engine came from a bike that was fitted with lighter CMA wheels many years ago, and these wheels didn't have a cush drive. Either this or a loose sprocket must have caused the damage.

Since I intend to fit a 5.5 inch rear wheel and 180 tyre, I bought a complete transmission from a later ZR7S, which has a slightly longer output shaft, while being surprisingly cheap.. 



ZR7S transmission..

Got the powder coated yokes and ZRX swingarm on the bike, along with the R6 forks, now with painted lowers. Yamaha Gold spot calipers and a XJR1300 front fender were then fitted. the latter will need small spacers and brackets to fit the lowers.

Working on the headlight mount and gauge mount, starting with simple template..










Test fit, this Koso gauge is only a tacho, won't be used, but at 80mm its the same size as the one the bike is getting.. 

Test fit of the R6 wheels before they go off to be coated, while gauge bracket done and now also needs to be ceracoated. Next need to make brackets for mounting the headlight.






 

Headlight brackets are now made in steel, painted and on the bike. Haven't fitted the the sealed unit yet as there are a couple of fasteners that need to be replaced, as they are the wrong size. The gold bars are just for setting up, they won't be used in the final build.


  

The ZR7S gearbox has bigger end bearings on its input and output shafts, and it wouldn't fit the GPZ750 cases. The shafts are the same diameter, but didn't want the hassle of stripping both the old and new shafts to change the bearings, with the risk of something going wrong. So picked up another transmission, this time from a Z750E, in excellent condition for only £30. Its fits fine.