Author Topic: Not so ultimate c-10 rebuild  (Read 17540 times)

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Offline Smooooth

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Re: Not so ultimate c-10 rebuild
« Reply #25 on: October 27, 2014, 01:09:29 am »
You're doing great!!!!!

Stephen
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #26 on: October 28, 2014, 12:33:33 am »
Thanks Stephen. I know you've been through this a few times as well. We were a little slow at work today so I managed to get the engine up in the frame. I've got a long way to go, but it basically will only take as long as it takes to get the remaining parts. I actually took a couple of pictures this time.
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 Smooooth

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Re: Not so ultimate c-10 rebuild
« Reply #27 on: October 28, 2014, 12:43:39 am »
You have reached that wonderful point in a build where you realize you have stopped taking stuff off and have begun to put stuff back on......

 :beerchug:

Stephen
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Offline connie_rider

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Re: Not so ultimate c-10 rebuild
« Reply #28 on: October 28, 2014, 12:50:27 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.

Jim Snyder did that install.

He Lives up in your area I think.
Ride safe, Ted
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #29 on: November 06, 2014, 03:04:31 am »
Things are coming along nicely. I cleaned up the inlet of the header pipes to remove the large weld bead and then installed the header with new sealing rings. Then I was able to install the radiator/oil cooler assembly and all the new hoses and water pump. Then the shifter assembly went on. I have also removed the swing arm to install the drive shaft and have decided to replace it with a new piece.
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 connie_rider

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Re: Not so ultimate c-10 rebuild
« Reply #30 on: November 06, 2014, 03:08:50 pm »
Woody, looks great!
A few quick questions:
I see you cut the weld humps out of your head pipes.
  Did you match the inlet diameters to your exhaust gaskets?
  Did you also cut the exhaust ports to match?

(I'm sending you a 1052 PM).

Ride safe, Ted
14 Connie (Traveler II) / 03 Connie (Buddy)
Gone but not forgotten; 87 and 00 Connies..

If your not already a COGger, "consider becoming one".
Help us make "OtP" possible again!!

Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #31 on: November 07, 2014, 12:40:42 am »
Thanks Ted. I did not match the pipe flange exactly to each exhaust port. The pipe flange is already much larger than the exhaust port opening. The biggest restriction is the huge weld bead just inside the inlet for the header. It really narrows the opening down. My main goal was just to smooth the transition from the port to the pipe to reduce turbulence. If you look at the inlet flange for the header, you can see that the work I did is more oval shaped than round and it is biased more to the top of the opening. That is so it more closely matches the port openings but in no way is "gasket matched".
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 Mcfly

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Re: Not so ultimate c-10 rebuild
« Reply #32 on: November 07, 2014, 01:00:07 am »
This is where it gets difficult.... it starts looking like a motorcycle, but it isn't yet!!  >:(

It's really coming along nicely, keep up the great work!   :beerchug:
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #33 on: November 07, 2014, 01:57:24 am »
Well.... look what was waiting for me when I got home. A new AGM battery, throttle cables, handle bars, and lastly the new drive shaft from Murph (THANKYOU Gary). I now have everything to finish putting the bike back together. I'm gonna be worthless at work tomorrow.......  :))
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 #34 on: November 08, 2014, 11:22:47 pm »
This is where it gets difficult.... it starts looking like a motorcycle, but it isn't yet!!  >:(

It's really coming along nicely, keep up the great work!   :beerchug:
Yeah no kidding. I am soooo close and yet there is a ton of stuff to do yet. I've been trying to change/improve stuff as I go along and it consumes a huge amount of time. A little more progress made on the Concours. The new drive shaft is installed and all the rear suspension is bolted back up. The new handle bars are installed and I have fabricated the mount for the HID ballast. It is double isolated with anti vibration bushings and the system is wired up as well. If I go to the shop tomorrow I will finalize the rear wheel install and possibly get the carbs bolted in. There is a good chance I will be done by next weekend....... just in time for that arctic blast that's coming......  :(
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 #35 on: November 10, 2014, 02:17:28 am »
Really getting close now. After having the rear wheel rebalanced, it is finally bolted on. After reinforcing the air filter box, it and the carbs were installed with new throttle cables. All that remains to make it run is to make a new wiring harness for the stick coil conversion, bolt on the new fuel petcock, and put some gas in the tank. I have already spun the engine over until the oil pressure light went out. Hopefully, I will attempt to start it Monday or Tuesday.........
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 connie_rider

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Re: Not so ultimate c-10 rebuild
« Reply #36 on: November 11, 2014, 03:10:07 pm »
GREAT!
 Keep us posted on the progress.
It's a shame about the Artic blast timing!

Ride safe, Ted
14 Connie (Traveler II) / 03 Connie (Buddy)
Gone but not forgotten; 87 and 00 Connies..

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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #37 on: November 12, 2014, 01:57:24 am »
Okay, here it is. 6 years ago this engine.... well some of this engine, lost oil pressure while riding to work. Initial inspection found lots of shiny metal flake in the oil. The low mileage donor engine from a 86 turned out to have a bent rod. Sooooo parts from this engine, parts from that engine, some new rod bearings and other bits..... and it runs again. No odd noises, no drips, idles smooth. I really can't be happier. Well, maybe when I actually get to RIDE it.  :motonoises:

http://s375.photobucket.com/user/txfatboy1/media/20141111_130610_zpscxcq0q9r.mp4.html
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 The Dude

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Re: Not so ultimate c-10 rebuild
« Reply #38 on: November 12, 2014, 03:45:03 am »
Hey hey!!  Nice work, Woody!  You said you'd have it running today, and you did it.  Now, hurry up and wait for the weather to warm up. ;)
Past: '84 KZ700, '91 VFR750
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #39 on: November 13, 2014, 04:31:00 am »
Thanks David. Man, it has been a long time coming. The only thing remaining on this bike that is from the factory original is the frame and the body panels. Nothing mechanical is the same as when it left the factory. Today it moved under its own power for the first time in 6 years. It was only a few feet, but the clutch was smooth, the transmission went into gear, the brakes are firm, and the side stand switch worked. Also confirmed the neutral switch and clutch switch function properly. I will do a couple of laps around the parking lot tomorrow and do another nut/bolt/leak check. I won't put the fairings back on until I have ridden it for a few days.
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 #40 on: November 15, 2014, 10:58:19 pm »
The weather report said it was going to be above 40 degrees F today sooooooo I need to try out my new heated gloves..... oh and my new front suspension, new 17 inch wheels, new bigger brakes, engine,...etc.   :motonoises:  First impressions are really good so far. Of course I wasn't able to actually enjoy much of the 18 miles because I was in hyper awareness mode listening for any odd noises, checking for bad smells, and paying attention to the overall feel of the bike. I does turn in really quick. The brakes are new so I'm still in the process of bedding them in, the tires are new so no pushing the limits until they get a few more miles on them, and the engine is freshly reassembled so just not wanting to press my luck just yet. I will say, with the only significant difference being the opening of the exhaust header flange this bike has a noticeable performance improvement over the 2000. It is much more responsive to throttle input and pulls in high gear a slow speeds with much more authority. It MAY be just because it's "new again" but it feels quicker. I've also got to learn how to adjust the zx9 inverted forks because it feels like ALL the adjustments are on full stiff.    :o  The lower panels will go back on when I am satisfied with the mechanicals.
I also can't thank everyone that provided parts, technical info, and advise enough. This bike would not have happened without someone else experimenting first and being gracious enough to share their knowledge.  :great:
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 Mo

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Re: Not so ultimate c-10 rebuild
« Reply #41 on: November 16, 2014, 05:54:08 am »
Congrats, well done.

Mo
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #42 on: November 16, 2014, 02:30:46 pm »
Thanks Mo. It was a fun project and I am lucky that I have the ability and the facilities to take on a project like this. It really means a lot to me because this bike was given to me by my Father as a way to get me BACK on two wheels. I  had been off for almost 10 years and we were able to do our first long distance ride together. There is a lot of value in this bike that will never add up to $$$$.

BTW, My Dad is a retired msgt USAF. He retired from Fort Gordon, Ga. in 1987.
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 Mo

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Re: Not so ultimate c-10 rebuild
« Reply #43 on: November 18, 2014, 10:40:00 am »
It's funny Woody, that's when I joined the AF. Please tell him thank you for his service and cherish the time you get with him on the bike.  I know when my dad was alive, some of the fondest memories were the motorcycle trips we took.

Mo
Retired MSgt USAF
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Offline txfatboy

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Re: Not so ultimate c-10 rebuild
« Reply #44 on: November 25, 2014, 02:51:49 am »
Okay, just thought I would post up a couple of pictures of the clearance between the Mean streak rear caliper and the right side saddle bag. As I said before, My reason for mounting the Mean streak wheel WITHOUT machining it was more of a "what if" reason than anything else. "If" the rear wheel gets damaged to the point of needing replacement while traveling, all I have to do is find a stock Mean streak wheel and bolt it on. No machine shop needed.  If I understand correctly, the reason for machining the wheel is to ultimately provide more clearance between the right saddle bag and the Connie rear caliper. There is about an inch of clearance between the caliper and the bag in the pictures. Also, the rear brakes are easy to modulate and don't seem to be any more prone to lock-up than the factory Connie brakes. I in no way claim this is better/easier/cheaper/etc. than having the wheel machined, just a different way.
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 #45 on: November 25, 2014, 03:07:39 am »
And she is done. All dressed up and ready to ride. Still need a few little things, bar end weights, paint the front fender to match, zzr1200 alternator,..... you know, little things..... Mounted the aux HID zenon lights to the hywy pegs and wired them so that I can switch them off/on independently from each other, added a separate ground wire from the engine block to one of the tabs for the stock coils. I parked the bike outside today and got several complements for how good it looked for being a 1991 year model bike.  ;D
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 connie_rider

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Re: Not so ultimate c-10 rebuild
« Reply #46 on: November 25, 2014, 01:21:20 pm »
So, have you done a twisty ride yet?
How does she handle?

Ride safe, Ted
14 Connie (Traveler II) / 03 Connie (Buddy)
Gone but not forgotten; 87 and 00 Connies..

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Help us make "OtP" possible again!!

Offline GF-in-CA

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Re: Not so ultimate c-10 rebuild
« Reply #47 on: November 25, 2014, 02:57:21 pm »
Looks great  :great:  :beerchug: What front fender did you use?  Let me know if you need info on adjusting the front end.
« Last Edit: November 25, 2014, 03:02:21 pm by GF-in-CA »
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Offline Steve in Sunny Fla

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Re: Not so ultimate c-10 rebuild
« Reply #48 on: November 25, 2014, 03:11:56 pm »
That's a super sharp bike there, woody. I think it might actually be convincing me to do a modern front end on Shoodaben.  >:D  Steve
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Offline GF-in-CA

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Re: Not so ultimate c-10 rebuild
« Reply #49 on: November 25, 2014, 03:16:41 pm »
That's a super sharp bike there, woody. I think it might actually be convincing me to do a modern front end on Shoodaben.  >:D  Steve

You know you want to Steve  >:D  :)
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