Author Topic: ZRX Front End Replacement  (Read 16463 times)

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Offline Dave Scott

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ZRX Front End Replacement
« on: April 23, 2012, 02:50:58 pm »
Ok, so here's the teaser.  Parts arrived over the weekend from CRocker for my ZRX front end upgrade.  I spent the weekend cleaning and inspecting parts.  seems a few small bits need replacing, but overall it should be a pretty easy replacement.  The most work will be to cut on the top triple to fit the ignition switch to it and have proper clearance.

No pics yet, so as I said, this is only a teaser.  Pics and progress to follow.

 :motonoises:
« Last Edit: May 08, 2012, 05:50:44 pm by Sport Rider »

Offline Bergmen

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Re: ZXR Front End Replacement
« Reply #1 on: April 24, 2012, 02:10:53 pm »
Yeppers, you're gonna love 'em:



Dan
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Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #2 on: April 24, 2012, 03:26:18 pm »
Hey Dan....what are your fork guards from?  From your original connie forks?  My ZRX did not have them with it.  when I looked at fische, it does not show the part.  thx....

Offline Bergmen

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Re: ZXR Front End Replacement
« Reply #3 on: April 24, 2012, 04:26:54 pm »
Hey Dan....what are your fork guards from?  From your original connie forks?  My ZRX did not have them with it.  when I looked at fische, it does not show the part.  thx....

The fork guards came with the forks which are 2003 model year. Many ZRX owners added a fork brace which requires removal of the bug guards, that is probably what happened to yours.

They are shown on the fische for the 2003 forks (55020).

Dan
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Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #4 on: April 24, 2012, 04:37:05 pm »
thanks Dan.  Interesting....that's the same part number as for the C-10.  Different sub-number though.  -1645 vs -1691.

« Last Edit: April 24, 2012, 05:23:15 pm by Sport Rider »

Offline Bergmen

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Re: ZXR Front End Replacement
« Reply #5 on: April 24, 2012, 05:02:17 pm »
thanks Dan.  Interesting....that's the same part number as for the C-10.

Does anyone happen to have a set from a connie they want to get rid of?

They are only $4.36 each from Ron Ayers (55020-1691).

Dan
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Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #6 on: April 24, 2012, 05:18:51 pm »
I gotta save their link.  I usually always go to bike bandit for OEM parts.  their price was $7.02 each.  By the time I paid their shipping it would have been 25 bucks.

Offline xjdaver

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Re: ZXR Front End Replacement
« Reply #7 on: April 24, 2012, 11:49:20 pm »
I'm not familiar with this conversion. So what his gives you is better choices for front tires and better brakes?
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Offline GF-in-CA

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Re: ZXR Front End Replacement
« Reply #8 on: April 25, 2012, 12:25:23 am »
I'm not familiar with this conversion. So what his gives you is better choices for front tires and better brakes?

In addition to the benefits you mention, it gives you:

-  Fully adjustable cartridge forks
-  Significantly stiffer fork tubes that virtually eliminate the amount of flex felt through the handlebars or in the chassis
-  A shorter trail for quicker steering
-  Tubular bar mounts to mate nearly any bend 7/8" handlebar you can buy or make
-  A near "bolt-in" installation

It does lower the front of the bike about an inch.

Gary F.

1998 ZGX1100
Central Valley California

Offline xjdaver

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Re: ZXR Front End Replacement
« Reply #9 on: April 25, 2012, 12:37:49 am »
Sounds good. Were all the handlebar mounted goodies a simple install?
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Offline Bergmen

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Re: ZXR Front End Replacement
« Reply #10 on: April 25, 2012, 12:53:41 am »
Sounds good. Were all the handlebar mounted goodies a simple install?


Here's a picture of the completed assembly (with handlebars off my 1985 Honda Nighthawk S):



Modified and powder coated upper triple clamp:



Completed assembly on bike:



Dan
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Offline xjdaver

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Re: ZXR Front End Replacement
« Reply #11 on: April 25, 2012, 12:58:52 am »
That looks great. Thanks.
87 ZG1000
82 Yamaha XJ550R

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #12 on: May 01, 2012, 04:12:10 pm »
Update:
Over the past week I got all the parts cleaned up and looking nice.  I also began work on the top triple to make room for the connie ignition.  My conclusion after doing all my cutting and grinding is that DAN does good work!  LOL  I can't say mine looks anyway near as good as what he did in the photos above, but at least I've gotten them to a point to drill and tap for the ignition switch bolts. 

I ordered replacement rubber bushings for the handlebar clamps, and also a spring for one of the brake calipers that was cracked.  I also noticed that the brass rebound screw at the top of the fork cap was beat to crap.  so much so that I could not get a screwdriver onto it to turn.  I'm buying a set of used caps to replace them.  One thing I found is that I am not experienced with forks with total adjustment. In all the bikes I've ever owned, this is the first this complex.  I got a service manual, but still trying to figure out how to get to the rod bolt to remove the cap.

Since I've not taken the connie apart yet for fitment, I may have to tweak, but I'm trying to get as far as I can before taking the bike out of commission.  That will include the ignition switch moving over, getting the fork oil replaced and the fork caps squared away, and double checking all the control swap over.  The other thing still on my mind is the handlebars.  I'm going to use the ZRX ones for the initial install, but expect I'll have to get taller ones soon after.  I was looking at ZRX risers, but I don't know yet if that will gain me enough.

I'll try to get some pics up tonight so you can see the progress, but no fair making fun of my lack of skills!   :))

Offline Bergmen

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Re: ZXR Front End Replacement
« Reply #13 on: May 01, 2012, 04:53:54 pm »
Update:
Over the past week I got all the parts cleaned up and looking nice.  I also began work on the top triple to make room for the connie ignition.  My conclusion after doing all my cutting and grinding is that DAN does good work!  LOL  I can't say mine looks anyway near as good as what he did in the photos above, but at least I've gotten them to a point to drill and tap for the ignition switch bolts. 

I ordered replacement rubber bushings for the handlebar clamps, and also a spring for one of the brake calipers that was cracked.  I also noticed that the brass rebound screw at the top of the fork cap was beat to crap.  so much so that I could not get a screwdriver onto it to turn.  I'm buying a set of used caps to replace them.  One thing I found is that I am not experienced with forks with total adjustment. In all the bikes I've ever owned, this is the first this complex.  I got a service manual, but still trying to figure out how to get to the rod bolt to remove the cap.

Since I've not taken the connie apart yet for fitment, I may have to tweak, but I'm trying to get as far as I can before taking the bike out of commission.  That will include the ignition switch moving over, getting the fork oil replaced and the fork caps squared away, and double checking all the control swap over.  The other thing still on my mind is the handlebars.  I'm going to use the ZRX ones for the initial install, but expect I'll have to get taller ones soon after.  I was looking at ZRX risers, but I don't know yet if that will gain me enough.

I'll try to get some pics up tonight so you can see the progress, but no fair making fun of my lack of skills!   :))


I carefully covered up all my hacking with powder coating, plus it is all on the underside where nobody can see it (heh, heh).

Check out this website for cool custom stuff for ZRX's:

http://www.pro-bolt.com/index.php/motorcycle/kawasaki/zrx1200s-01-03.html?p=1

There are others, I just don't have links for them. I want to replace my fork caps + adjusters since mine are boogered up also. As for the adjustments, I just went with the manual recommendations for damping (compression and rebound) and backed off the spring preload all the way. Haven't touched it since and the forks are working perfectly right now.

Dan
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Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #14 on: May 01, 2012, 06:20:03 pm »
I suppose the spring preload may be due to the additional weight of the connie, but interesting none the less.  How much sag are you getting at that setting?  I'm only familiar with my track bike trying to get it to 30 mm.

Offline Bergmen

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Re: ZXR Front End Replacement
« Reply #15 on: May 01, 2012, 06:35:49 pm »
I suppose the spring preload may be due to the additional weight of the connie, but interesting none the less.  How much sag are you getting at that setting?  I'm only familiar with my track bike trying to get it to 30 mm.

I have no idea. When I first installed the forks the compression and rebound damping were set to the max and the spring preload was all the way in. It rode like a buckboard so I backed everything off to the minimum and all is good.

I'm afraid to change the fork oil because I don't know what is in it. I am the third owner of the 2003 ZRX1200R that the forks came from and the 2nd owner does not know if springs or fork oil was changed. It rides so nice now that if I change the oil to something different than is in there it could muck things up. Since it takes an act of Congress to change the fork oil, experimenting with this or that isn't in the cards.

Dan
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Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #16 on: May 01, 2012, 06:43:25 pm »
if your fork oil looked like what I dumped out of mine, you'd change it.  Man was it bad.

I'm not overly worried about settings except that they aren't harsh.  I figure even is not "perfect" it will be far better than the stock front suspension.  :)

Offline GF-in-CA

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Re: ZXR Front End Replacement
« Reply #17 on: May 01, 2012, 11:58:37 pm »
Sport Rider,

If you can get the sag close to the 30 mm number, I would start with the rebound and compression at their minimum.  You may find that to be good or if not they are really easy to adjust.  You probably already know this, bu try to get to the minimum amount of compression needed to keep from bottoming over sharp bumps.  For rebound, try to get just to the point of feeling no bounce in the front. 

As for getting the cap off the the damper rod, I am not familiar with the ZRX forks, but if they are similar to other cartridge forks I've worked on, the key is to get the spring compressed enough to get a wrench on the lock nut underneath the cap.  Then it's a piece of cake to get the cap off and the spring out.  You can make a tool to do this, or Racetech makes a really expensive tool for this purpose. 

http://www.racetech.com/page/id/70

I put the fork in a vice and use a combination of long bar clamps and a couple pieces of wood clamped around the spring collar.

HTH,
« Last Edit: May 02, 2012, 12:03:18 am by GF-in-CA »
Gary F.

1998 ZGX1100
Central Valley California

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #18 on: May 02, 2012, 01:29:10 pm »
Thanks for the feedback Gary.  That's exactly what I did with the nut last night and got it off no problem.  There was not anything specific in the instructions and my brain farted about just compressing the spring.  duh!   :-[

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #19 on: May 02, 2012, 01:30:04 pm »

I have no idea. When I first installed the forks the compression and rebound damping were set to the max and the spring preload was all the way in. It rode like a buckboard so I backed everything off to the minimum and all is good.

I'm afraid to change the fork oil because I don't know what is in it. I am the third owner of the 2003 ZRX1200R that the forks came from and the 2nd owner does not know if springs or fork oil was changed. It rides so nice now that if I change the oil to something different than is in there it could muck things up. Since it takes an act of Congress to change the fork oil, experimenting with this or that isn't in the cards.

Dan

Hope your oil looks better than this!   :o

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #20 on: May 02, 2012, 01:31:15 pm »
You can't really tell from the picture how poor the brass screw was.  The groove you see is what I cut into it.

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #21 on: May 02, 2012, 01:33:35 pm »
pictures of the hacked up top triple and a few others.

Note on the brake calipers there is a red arrow to the crack in the "spring" on the back it.  I've got the new one to replace it.

Offline Bob_C_CT

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Re: ZXR Front End Replacement
« Reply #22 on: May 02, 2012, 02:12:24 pm »
Sport Rider, I'm in the midst of doing the conversion too. Had a little trouble with a mismatched lower and upper triple that had different offset for the steering bearing post, that's resolved. I mounted upper and lower triple, fork tubes, handlebars and wheel last night, still have bike up in the air, on centerstand, jacked up under engine. I'll have to see how it comes off of cstand (1" lower in front) more importantly how well it goes back on cstand.

If you haven't found out already the ignition is easier to unplug and plug with the lower triple removed and the upper just laid out of the way.

I haven't gotten the ZRX manual I purchased so I haven't torqued everything down to spec yet. Can any of you ZRX guys share torque specs on upper and lower triple, steering stem, axle, axle pinch bolts and caliper bolts?

I have ZRX bars with the risers, definetly higher than stock connie I would say at least an inch. I will get pics so you can see what it look like with them.

I have to install calipers, bleed brakes, put on fender, and some other odds and ends.  Looking good, I'm hoping to be done by this weekend. Not a big fan of the plain jane fender but it will have to suffice for now, but need to order fender extender. Pix to come.
Good Luck
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Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #23 on: May 02, 2012, 02:24:02 pm »
Bob, what are you using for the fender?  the stock ZRX one?  I have a stock that was trimmed down with what I have.  Eventually I'll replace it, but will be using for now.

check this link.  you should be able to find torque specs in one of the links.
http://home.comcast.net/~bignuts/site/?/page/1100_Manual/

Offline Bergmen

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Re: ZXR Front End Replacement
« Reply #24 on: May 02, 2012, 02:27:45 pm »
Hope your oil looks better than this!   :o

That actually looks better than some of the gack-spooge-mung I've drained before. You're going to strengthen my guilt complex now, right at the start of the riding season...

Dan
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