GOOSE 2 (2021)

KAWASAKI MFP1000-Z

BY: DAVE MARSDEN





THE GOOSE 1

(PICTURED ABOVE: THE GOOSE 1)


It`s been over 12 years since i built the Jim 

Goose replica bike.

It cost a fortune to build and once finished i really struggled to sell it. Since then i could have sold it 20 times over for more than 5 times what i finally did sell it for. I was obviously well ahead of my time?

Well, the time as come, the time to build another replica.

I have a Z1000 donor bike and i am currently collecting the relevant parts to build this Mad Max classic motorcycle.

If you’re a fan of the original 1979 Mad Max film by George Miller, then you likely remember the character Jim Goose, often referred to simply as Goose or The Goose. He’s a relatively minor character in the movie but he certainly made a big enough impression to get remembered. 

"SEE YOU ON THE ROAD...SCAG!"

So begins the MFP1000.

Originally,way back in 2009 i just bought a "KIT" from the Whitehouse company in Japan. This kit was actually for the Zephyr 1100 model but i easily modified it to fit the Z1000 i had.

Whitehouse have long since discontinued this kit, so my job is a lot harder now.

The fairing and tailpiece is now being reproduced by a company in the USA.

 I located AIR-TECH in California, and ordered and took delivery of their replica bodywork kit. Nice bit of kit but it comes unpainted, undrilled and with no screen and no brackets, and of course none of the MFP badges or any of the "police" equipment, so the job gets even harder. I see a few weeks of trawling the internet in store for me.......

CLICK HERE FOR Air-Tech web site


I had to start somewhere so a complete strip down of the donor bike was required.

Needless to say there was a bit of work to do on the frame before i could get it powder coated.

Various brackets were bent and there was a few broken and snapped bolts, so a trip to see Tony at Pitstop motorcycles  (01942 684684) was needed to get a few quick repairs. There is nothing this guy can`t do and he was soon down on the floor, welding, grinding and making sure the frame was straight enough for the next stage.

Here he is, doing what he does best !!!!

 

CLICK HERE FOR PITSTOP`S WEBSITE


The kit from Whitehouse came with a specially designed fairing bracket for both the top and bottom fairings and was an easy fit. Trying to make one like this would be quite difficult so I am going to make up something the best I can using a combination of whatever Kawasaki parts we have in stock at Z-power and some one off 3D printed parts. My son has access to both a standard 3D printer and a “metal” forming 3D printer as well as a plasma cutting machine.

He has already started to make me some headlamp brackets and the initial top fairing brackets. Here he is, hard at work…..


Once Tony had done the repairs on the frame we took it over to our good friend "ROGER" to get it checked over on his frame checking jig. Nothing wrong with it but it is always worth checking. Cost is a few hundred pounds but well worth it just for the peace of mind.....


I have already stripped down the engine and have sent it to Steve Smethurst for cleaning and polishing. Click on the picture below for Steve`s details. The Zinc plating has gone away for re-coating and i have given Phil at Z-power a big list of engine parts that i will need, all new cam chain parts, 1st oversize piston kit, new seals and gaskets, new bearings and a new set of valves plus all the usual engine parts that i use on a full rebuild. Not cheap but once you have a motor in pieces it makes sense to replace all those wearable parts. I normally budget for around £1700 for the parts, £500 for the cleaning/polishing and another £400 for the specialist services like the rebore and cylinder head work. We trust this work to Paul at Engine-Teknics in Westhoughton. (01942 840818)

We recently made a new contact for metal refinishing, Steve Kormoss here in Manchester. (07902 589167) Steve does a line in XLYAN coating, sort of a ceramic finish. He has done the brake calipers for us, excellent finish, looks just like the original finish but much more durable. Cost is around £60 per caliper. 

I got them back from him and fitted them with new pistons and seals. New pads and clips will be fitted later.

****************************************************************************************************************************************


All the engine parts are back now from Steve Smethurst so i can begin to build the engine. The main stay of the engine has been finished in its original bright alloy look and the outer engine covers  highly polished polished.

I know it`s not cheap but Steve`s finish is quality work and much more durable then bead or vapour blasting.

                  


***********************************************************************************************************************************************************

Well, with all the engine parts back  and my big box of new parts from Z-power, i decided to have a weekend of engine building.

I normally build the bottom end of the motor and then fit it into the frame and then fit the top end but i decided because the frame was still at the powder coaters that i would just assemble the whole engine and fit it in the frame complete. Makes the job a heavy job but i had a free weekend so i took advantage of this and cracked on. The bottom end goes together quite quickly, not much to do except fit the new cam chain and gearbox/clutch bearings. New clutch plates and springs are fitted along with a new starter clutch repair kit and bearing. All new gaskets and seals are used along with a new oil filter.

 The top end is the tricky bit but after a couple of hundred of them i find it relative easy....

I fitted one of Z-power`s 1030cc high compression pistons kits. Engine-Tecknics had already carried out the rebore on the STD bores (cost is around £160) and they also carried out the head work. Normally this requires checking and re-sleeving the valve guides, we rarely replace the guides these days, re-sleeving is a much better and economical way of doing it. Then the new set of 8 valves are seated into the re-cut valve seats and the surface of the head skimmed flat. You can expect to pay around £150 for all this work. All new cam chain tensioners and guides are fitted along with new valve seals and gaskets. Valve inner and outer springs are checked for wear and fitted along with the other valve parts. Rarely do the springs need replacing but always worth checking. Once assembled and the cam timing checked then the valve clearances are checked and new valve shims are used to adjust it to the correct settings. The ignition system will be fitted later, we normally fit a DYNA-S ignition system. The original points/condenser set up is good enough but we fit the electronic system for peace of mind.



*************************************************************************************************************************************************************************


Well the powder coating has returned so i wasted no time in getting it prepared which means running a tap through all the threads and removing all the masking tape. First job was to fit a set of Taper roller headbearings.

Because the engine is in one piece i decided to "cheat" and fit the frame over the engine by lying the motor on its right side and then carefully locating the frame into the relevant position. This makes sure non of the frame gets scratched.

I prepared it with some protective duct tape just to make sure...... You only then have to fit the bottom rear and top front engine mounts and bolts and it is then secure enough to lift up.. Easy-Peasy.....



Then we the help of my good friend Trevor, we lifted it onto the work bench. At this point i fitted the rest of the engine mounting plates and the relevant bolts.

I just need to go through the rest of the powder coated parts now and prepare them for fitting