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This project is going to be restarted shortly... this page will be redone showing the assembly of the z1a as seperate pages (Running frame and engine assembly).
Introduction
This restoration project is a 1974 Kawasaki z1A that was purchased in 1999/2000 from an auction site (not eBay) for $1450 AUD site unseen. It was 99% complete but was showing at least a decade of neglect and rather than use it as a parts bike, I decided it would make an ideal restoration project.
The bike had at some stage of its life been a typical 1970's / early 80's show bike with everything chromed (And I mean EVERYTHING)!
When I first saw it, the chrome had peeled off most of the alloy parts and rust was starting to appear on most of the steel parts. The alloy was tarnished and showing corrosion from the previous owners (PO) neglect. The PO had replaced all the bolts with plain steel allen key set screws and these had rusted everywhere.
A full restoration of every component was required and all the missing parts were sourced from eBay over a 3 year period.
This is what a completed 1974 z1A should look like. There are 3 different paint jobs available.
Initial Work Performed
The bike was totally disassembled in one go and then the frame and swing arm were powder coated a gloss black with new brass bearings fitted to the swing arm on re-assembly. The forks where sent in to get the hard chrome re-done and the lower legs where sent in to get polished. Anything that was steel was either chromed or powdercoated as per original specifications. The rear shocks were missing and a second hand original pair from another z1A was sourced from eBay in the US and purchased for $20 plus $25 shipping, then sent in for a full rebuild at RAD shocky repairs.
All fasteners have been replaced with stainless steel metric 304 allen key bolts and set screws. Metric fine bolts were manufactured from large shanked coarse thread bolts with the thread re-tapped on the shank (thats a usefull tip to remember!). Thanks to my friend Dave Sloan for manufacturing those. (I need more done ;)
The "Before" Shot
The engine has just been removed form the frame, it was painted black and the cases where chromed. The z1A was not painted black by the factory so for originallity the paint wont be re-done. The chrome has lifted on all the cases as a result of the years of heat and cold stress. Instead of stainless fasteners, this one featured brown rusty fasteners... not a good look!
The "After" Shot.
After water blasting and polishing of the cases. The engine is temporarily assembled to show the effect of the cleaning process and the contrast with the polished covers. The camshaft cover has since been done.
The finish on the barrels shows the quality of the water blasting work, the barrels have come up perfect and now only need measuring with a inside micrometer, a light hone and new rings inserted.
Re-Evaluation of work to be done
Engine Work:
Obtain oversize rings and install pistons, then barrels.
Repair helicoils in cam caps and assemble head.
Install head onto engine block.
Rebuild carburetors with new kit.
Frame Work:
Obtain domed fasteners for handlebar mounts.
Get brake fasteners zine plated and install.
Install master cylinder and bleed brake assembly.
Fit and adjust rear brake.
Verify wiring harness and check electrical system.
Paint tank, side cover and duck tail in original paint style.
Final Assembly:
Install engine and connect ignition components.
Install carbs and airbox.
Install exhaust system.
Fit body work and install battery.
Tune and ride!
Work History
With so many bikes on the go, the z1A slipped to the back burner. I have decided to restart documenting the progress done on the bike and complete the running frame. I also intend on finishing the motor, install it and then source a new exhaust system for the bike prior to painting it. Then classic registration will be sought.
The previous progress is documented below.
Current State - September 2009
Most of the engine and frame parts are stored in containers, the frame is on wheels and can be rolled around. During the original assembly work, some custom parts were fitted that now detract from the factory restore I now want to do on the bike.
I intend on removing the non standard parts and use them on my z1000A2 project. I also need to source most of the fasteners from my boxes of old bits and get them zinc plated again. At one point I rushed to replace everything with stainless and now think the original fasteners would be better for this type of restoration.
October 2007
I'm glad I dated all the section of this project, with so many bikes on the go its easy to see how something drops behind. I recently got back into the z1a reassembly by working on the head, I fitted all the valves and then put the cams in but discovered there where helicoils fitted in each of the four cam holders, so someone did a bad job on the head at some point in the past.
While I was working on the engine I tried to fit the barrels and pistons but broke a ring! You would not believe how many swear words can come out in a 3 minute rant! I soon discovered that the rings are the wrong size. The engine appears to have been over bored to 50thou oversize.
I will be sourcing some 1st oversize rings from the US in a future order.
October 2006
Engine re-assembly begins......
With all the engine components blasted clean and most of the frame finished, I now only need to assemble the engine back together. Before I started I chased up a full gasket set, oil seals, 3M Three Bond and a Stainless Steel engine screw kit from eBay (I needed the long screw that are not available locally).
The bottom end is reasonably easy to put together, my best suggestion is to study the workshop manual in great detail and make sure everything is torqued correctly (thats a hint to buying a torque wrench - you need two sizes one to do inch-pounds and one to do foot pounds). While the case half's are apart I put a new cam chain in it which I purchased from z1enterprises.
When assembling the engine use heaps of engine assembly lube in case there is a delay it will stick till the oil flow flushes it away after a few miles.
