Just in Time: KAWASAKI ZEPHYR1100 Custom by Shabon Dama

Shabon Dama's ZEPHYR1100

Lightening the weight and handling of the machine, and on top of that, increasing the controllability and sense of ownership. This theory established by Shabon Dama for the Zephyr 1100 is also applied to this Red Tiger machine. At first glance, you can feel the compactness of the bike. "This bike adopts the 17-inch wheel specifications and suspension configuration that we proposed at an early stage. The exterior paint job and frame cleanup had already been done, and all that remained was the engine. Since most of the original internal parts are no longer available, we decided to work on the engine while we could so that the owner could continue to ride the machine as long as possible. The interior was given an overhaul menu of checks and corrections, and the exterior was given a titanium-colored Gun-Kote finish. Now the entire bike is clean both inside and out, and I think you can ride it as if it were a new 17-inch Zephyr without any worries," said Mr. Kawase, who was in charge of this build.

Indeed, this is exactly the kind of work that you would want to do if you were building a Zephyr with the 17-inch specifications that are expected today. "We were going to work with the stock 1062cc displacement, but the stock pistons are no longer available, so we had to do a lot of searching. We happened to come across a piston that was 0.5mm oversized from the stock piston, and we assembled it. It was good luck that we were able to find the right one," Mr. Kawase continued. It seems to be a common opinion that if you feel the engine of your Zephyr is deteriorating or you are thinking of modifying it, you should make a decision as soon as possible and consult with a shop about the work to be done. Like Mr. Kawase, Mr. Ito, who takes care of the heavy work at Shabon Dama, explains, "The body can be customized in various ways, but the engine is really difficult. The transmission is also at a level where we can't take countermeasures if damage occurs to the first gear, which is the weak point. The only way to fix it while it is still usable is to apply surface treatment such as WPC and assemble it with severe clearance adjustment between the gears. There are no cranks and there is only some crank metal. The same is true for the big parts, but even more painful is the lack of gaskets and internal oil lines. Even if we try to use used parts, the number of good quality ones is decreasing rapidly. We try to make each machine as good as new when they come in, but we can't expect to be able to get all machines to a fully new condition in the future. For example, even if we say, 'I was planning to do this at that time,' three years from now the parts situation will probably be even worse, and it will be too late. I think such a possibility is becoming more and more realistic. So if you are thinking of working on the engine, please do it as soon as possible." His words sounded quite tense. But he is not being pessimistic. It is advice for those who want to continue riding and keep their machines in good condition. If you do the work now, when it is still manageable, you will have a better understanding of the current state of the machine, and it will definitely extend the life of the bike. This is because they have seen many machines, examined their parts, and made arrangements for them. A sense of urgency is understandable because there are many staff members who ride Zephyrs and ZRXs. This bike can be said to be an example of one that made it in time.

Handle

The steering stem is a Shabon Dama Short Offset Stem Kit Wing Type. The damping force adjustment dial and initial load adjustment nut can be seen on the top of the Hyper Pro Front Forks. The handlebars have been converted to tapered bars, and a Yoshimura Progress Meter has been added in the center. Both left and right masters are Gale Speed.

Bodyworks

The fuel tank is a straight Z2 type and is finished in Red Tiger color with painted KAWASAKI emblem. The seat is a Supreme Seat.

The tail cowl is a Shabon Dama Plain Weave Carbon Tail Cowl for Zephyr 1100 (the paint is left so that the carbon base can be seen) for a long tail specification.

Engine

The engine, which also features a Moriwaki Plug Cooler that directs airflow to the cylinder head section, was assembled with 0.5mm oversized pistons from the stock 1062cc (φ73.5 x 62.6mm) and recalibrated in various parts. The exterior of the engine was also finished with a titanium-colored Gun-Kote. Previously, many polished parts were used, but this time, they decided to go with a calmer style.

A Yoshimura TMR φ38mm carburetor is used. In addition, a heat guard plate is used to reduce heat transfer from the engine.

Chassis

The machined aluminum frame side covers are by Shabon Dama. The step kit and sprocket cover are by Moriwaki, and the clutch release is by K-Factory. The drive chain is by EK ThreeD.

The front forks are Hyper Pro φ43AH1 and the front brakes are a combination of Brembo Axial CNC 4P calipers + Sunstar Works Expand Discs.

The suspension was built early on, featuring the Hyper Pro DP-S for the rear suspension and black-finished Wheelie swingarm. The wheels are forged aluminum Gale Speed Type-GP1S Wheels, sized 3.50-17/5.50-17, replacing the stock 3.00-18/4.50-17.

For the rear brakes, a Brembo CNC 2P Caliper and Sunstar Works Expand Disc are selected.

Gallery

Specifications

About Shabon Dama

Shabon Dama offers many custom parts mainly for Kawasaki Z1, ZEPHYR series, GPZ serices and other retro bikes. They are offering unique and originality-focused products such other can't copy. The full customization of your Kawasaki retro, vintage bike, Shabon Dama is the brand worth considering for JDM originality!

Shabon Dama brand page

Original Source of this Article

Heritage & Legends