Author Topic: Not so ultimate c-10 rebuild  (Read 18226 times)

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Offline txfatboy

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Not so ultimate c-10 rebuild
« on: November 24, 2013, 06:48:52 am »
One of my long term projects has been rebuilding/updating my 90 Connie. Thanks to this fantastic source of info, over the top generosity of others, and some great deals/finds on ebay, I have acquired enough parts to start my own upgrade project. I just about have the chassis/brakes sorted and am only needing some zx10b rods and I can start reassembling the engine. The project entails 17 inch wheels, inverted forks from zx9/7 combo, ZZR rear shock, 1052 build which will eventually have SISF's cams, jet kit, and a modified exhaust, stick coils, block off plates, cruise control, etc.. I did differ in the Mean Streak rear swap in that I did not machine the wheel. I used an unmodified wheel, caliper, and rotor from a Mean Streak. I boxed/reenforced the Connie swing arm and added a lug to bolt the Mean Streak caliper bracket down. Then all I had to do was have the caliper bracket thinned down slightly to match the thickness of the Concours caliper bracket. This will allow me to use a stock wheel, caliper, and rotor from a mean streak without having any machine work done, and, I can swap right back over to a Concours setup if needed.
Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.

Offline Steve in Sunny Fla

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Re: Not so ultimate c-10 rebuild
« Reply #1 on: November 24, 2013, 12:16:47 pm »
some cool ideas there, in particular the swingarm mod. I like it! it ought to be a very nice bike when you're done. I have an 01 I'm thinking of doing similarly, your method of swingarm mod might just get "borrowed" - Steve
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Offline WillyP

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Re: Not so ultimate c-10 rebuild
« Reply #2 on: November 24, 2013, 12:38:55 pm »
Nice... but what's the sticker on the fork? I'm not saying what I think it says.  :-[
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Offline Mcfly

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Re: Not so ultimate c-10 rebuild
« Reply #3 on: November 24, 2013, 01:43:57 pm »
Nice work!!  Certainly putting lots of SPORT in your sport tourer.   :motonoises:      :beerchug:


Perhaps a silly question, but, is there a enough clearance between the rear brake and the right pannier?
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Offline Bergmen

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Re: Not so ultimate c-10 rebuild
« Reply #4 on: November 24, 2013, 03:52:30 pm »
Wow, very cool! Nice work!

Keep us up to date...

Dan
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #5 on: November 24, 2013, 05:40:13 pm »
Thanks Guys. I have to say, this project wouldn't have even started if it wasn't for all the info I was able to "borrow"  ;D .

Nice work!!  Certainly putting lots of SPORT in your sport tourer.   :motonoises:      :beerchug:


Perhaps a silly question, but, is there a enough clearance between the rear brake and the right pannier?
Lots off room, The caliper sits in the cut-out of the saddle bag.

Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.

Offline turbo-max

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Re: Not so ultimate c-10 rebuild
« Reply #6 on: November 24, 2013, 05:56:56 pm »
 :great: nice, i love it so far!!! great work
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Offline Mcfly

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Re: Not so ultimate c-10 rebuild
« Reply #7 on: November 24, 2013, 06:33:06 pm »
Outstanding...  You get a one to two pot brake upgrade outta the deal too. 
Just keeps getting better...   :great:


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Offline Smooooth

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Re: Not so ultimate c-10 rebuild
« Reply #8 on: November 25, 2013, 12:07:54 am »
Very Very Nice Work!!!!

Ideas bouncing around in my head..................

Stephen
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Offline AirMonger

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Re: Not so ultimate c-10 rebuild
« Reply #9 on: November 25, 2013, 01:24:13 am »
And I thought the single pot was prone to locking up! Your gonna be in the Motard class now :). Whahoooooooo
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Offline Hazy

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Re: Not so ultimate c-10 rebuild
« Reply #10 on: November 25, 2013, 03:43:51 am »
Tell me more about the rear shock. What year and model did this come off of? Is this a direct bolt on? Would love to upgrade the my shock, if the price is right of course. :)
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Offline GF-in-CA

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Re: Not so ultimate c-10 rebuild
« Reply #11 on: November 25, 2013, 03:51:13 am »
Looks great so far, txfatboy.  Seeing how I've done everything you described, I predict you'll be extremely happy with the finished product  :)  I certainly am!  Looking forward to seeing your progress.   :great:
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #12 on: November 25, 2013, 11:31:40 am »
And I thought the single pot was prone to locking up! Your gonna be in the Motard class now :). Whahoooooooo

No biggie for me, I've been using the rear brakes as habit for a long time. When the Connie is loaded 2 up + gear, I like to use all the brakes I can.... Heavy on the front brakes on initial apply then apply the rear until the a**-o-meter tells me when it's enough.

Tell me more about the rear shock. What year and model did this come off of? Is this a direct bolt on? Would love to upgrade the my shock, if the price is right of course. :)

The rear shock is from a ZZR1200 (all years IIRC) I made a simple bracket to mount the preload adjuster and trimmed the edge of the side cover flush. Its close but it fits, looks like it came from Ma Kaw that way. I was very lucky, mine was a brand new "take-off" with a claimed 0 miles (It looked fresh off the assembly line), delivered for only $75.00 off of ebay. There is a ton of info on what it takes to mount this and other shocks. I chose to use the ZZR1200 because I got a great deal. Just make sure, if you use the ZZR1200 rear shock, make SURE you get the LOWER mounting bolt and bushing. The Concours lower bolt will not work.

Looks great so far, txfatboy.  Seeing how I've done everything you described, I predict you'll be extremely happy with the finished product  :)  I certainly am!  Looking forward to seeing your progress.   :great:

Thanks Gary. Its because of you, Steve, Dan, Tony, and others and all the time and effort y'all put in that make this possible. Except for the "vibration" issues I love this bike. It does everything I want in a bike and I ride almost everyday. The trunk and bags make it very versatile, and with the help of Steve, the 2000 is peppy enough to keep things interesting. I have acquired a cd from Dan, and if I ever come across a 1200 engine within my budget, I'll do that as well.
Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.

Offline WillyP

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Re: Not so ultimate c-10 rebuild
« Reply #13 on: November 26, 2013, 12:47:53 am »
And I thought the single pot was prone to locking up! Your gonna be in the Motard class now :). Whahoooooooo

I remember way back someone had used a front duel pot caliper on the rear, and reported that it was actually less likely to lock, as the duel pot gave better control over the braking pressure. Makes sense, because, per given travel of the foot pedal, you are still pushing the same volume of fluid into the caliper, but with a larger piston area, the pad will move less distance. Or in other words, that 'point of lock-up' will be spread over a slightly longer pedal travel, giving finer control.
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #14 on: March 08, 2014, 06:38:00 pm »
Well Just a small update so far, I got the last little bit of machining done to the lower triple clamp bushing so the Connie stem would be at the correct height. I also made a simple press to push the fairing frame out a little so that the lower triple clamp would clear. I did a final mock-up of the front end and everything bolts up like it came that way. The new bars and bar mounts/risers will be delivered soon so that I can mount the bars and figure out how long the brake and clutch lines need to be. I also FINALLY found a local small engine machine shop that can bore the cylinders for the zrx pistons and I FINALLY found a set of zx10b rods that are in pristine condition. The machine shop says they have a lot of experience with the water cooled Kawasaki inline 4s.... Now I have to work on freshening up the head and get in touch with Steve about some cams and jet kits for the carbs. Oh, and I'll be on the look out for a zzr alternator as well.
Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.

Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #15 on: March 25, 2014, 12:17:29 am »
Okay, I have tried twice to add an update with pictures and couldn't get it to work. I thought the pictures might have been too big so I resized them and gonna try again. The rods are almost ready to go, and I got the cylinders back from the machinist. I also got the bars and risers mounted but the bars are only temporary. Now I'm looking at the head thinking I should have been working on it while I was waiting for the other parts to arrive......  ???
Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.

Offline Bob_C_CT

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Re: Not so ultimate c-10 rebuild
« Reply #16 on: March 27, 2014, 02:29:46 pm »
Nice looking. Good idea on the rear wheel install. I like the placement of the rear shock adjuster. Keep up the good work. Those zrx motors are pretty costly. That's for one without carbs alt and starter on top of it.
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #17 on: April 09, 2014, 02:15:41 am »
Thanks Bob_C_CT.  Ive been working on this bike for a while. I just finished bolting the front end back together and I have started working on the engine. I can't wait to ride this thing.
Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.

Offline pat.mckinney1

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Re: Not so ultimate c-10 rebuild
« Reply #18 on: April 11, 2014, 11:15:41 pm »
I've got my mean streak sitting in my dad's driveway that I blew the motor on before I bought my concours. Sounds like I'm about to cannibalize the meanie. 

Quick question. Did you use the brake hose from the mean streak as well?

Offline pat.mckinney1

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Re: Not so ultimate c-10 rebuild
« Reply #19 on: April 11, 2014, 11:19:10 pm »
And how much did you shave off that caliper bracket? Can you do it with a grinder?

Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #20 on: April 12, 2014, 02:47:49 am »
The rear brake hose is a braided steel line from PinWall on ebay. IIRC it was about 21 inches long. The bike is at the shop so I can't measure it at this moment. The brake caliper bracket was narrowed 0.09 inches on each side at every hole except the recessed side for the bolts that bolt the caliper to the bracket. I also had to do some very minor grinding on the inside face of the caliper bracket to give the rear rotor bolts some room. After having the bracket narrowed, I bolted the wheel on, found a bolt that fit the threads of the caliper bracket and cut a steel sleeve to length and bolted the sleeve to the caliper bracket so I could locate where to weld the sleeve onto the swing arm. The Meanstreak bolts the caliper bracket  in a similar position but that part of the Meanstreak swing arm is a thick cast piece. This area on the Concours swing arm is thin sheet metal that is not designed for the bending loads that would be applied. That is why I boxed the area with 1/8 inch steel plate. It didn't add much weight but significantly stiffened the swing arm in that area.
As far as using a grinder, well I guess you could but EVERY mounting surface on that bracket needs to be flat and parallel and perpendicular to the axle center line so that there is equal/even pressure on the bearing on that side and so that the brake pads are parallel to the rotor.
 
« Last Edit: April 12, 2014, 03:05:36 am by txfatboy »
Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.

Offline WillyP

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Re: Not so ultimate c-10 rebuild
« Reply #21 on: April 14, 2014, 02:11:56 pm »
If you really want to try milling it yourself without a mill, I have had some success milling aluminum using a router bit chucked in a drill press.
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #22 on: July 10, 2014, 03:28:18 am »
Well I finished reworking the head. I took everything apart, cleaned and inspected the parts. The cam lobes looked almost perfect except for one VERY small pit on one cam lobe. I cleaned off all the carbon from the ports (the exhaust had more build up than I expected) and chambers and lapped all the valves. New valve stem seals and put everything back together. Hopefully I will be able to start bolting the engine back together soon. I need this thing running or close to it before mid September because the 2000 is going back to Salt Lake City area to stay.
Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.

Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #23 on: October 18, 2014, 03:37:35 pm »
Well, there has been a SLIGHT change of plans. I have decided to put the 1052 build on hold (temporarily) and have proceeded with the stock cylinders/pistons/rods. The reassembly is pretty straight forward with the exception of some oil system mods. These are well documented and are more of a "might as well since its already apart" thing. I took the main oil feed pipe and removed the overhang/restriction at both ends inside the tube, enlarged the main oil passage inside the plate that feeds oil from the filter to the main pipe, and shortened the oil filter bolt to prevent a partial blockage of the now larger oil passage. 
I have another complete bike build to do after I finish this one. This one will be optimized for single rider and the other will be set up biased for 2-up. Doing it this way, I will have a dependable stock engine and a spare bike to "play with". It has always been my intention to swap a ZRX 1200 into the "90 anyway and have the 1052 in the 2-up bike.
Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.

Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #24 on: October 27, 2014, 12:25:02 am »
Getting soooo close. I installed the 2min. mod jet kit, new float needles from Murph and set the float levels on all the carbs. I also got the exhaust cam gear from Steve and installed it as well. Then The star springs went on and the side cover was installed. The engine is finally ready to install. Hopefully the engine will be bolted in before the end of the week. If things progress smoothly and the rest of the parts arrive quickly, I'm hoping to have a running/rideable Concours in less than 3 weeks.
Woody

2014 V-Max Matt Gray, air box and exhaust mods, reflashed ECU, now over 200 hp. Currently accepting donations for rear tire money.......
1991 Connie, 17 inch wheels, modified swing arm, ZRX1200 forks with full race tech gold valves a springs  and 6pot Calipers, zx9/ zzr1200 hybrid rear shock, 2 min mod and exhaust cam sprocket from SISF, tubular handle bars, hywy pegs, HID headlight and running lights.