Author Topic: ZRX Front End Replacement  (Read 16489 times)

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Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #25 on: May 02, 2012, 02:29:17 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

yeah, I figured when I posted it I would make you feel guilty.   :beerchug:

FWIW, the service manual says 10w.  That's what I'm going to use for now.  If I feel necessary, I'll change it, but guessing it should be fine with that.

Offline WillyP

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Re: ZXR Front End Replacement
« Reply #26 on: May 02, 2012, 02:29:37 pm »
guilt complex

Ah, the skeletons in the closet! Only the shadow knows!  :))
Smart people look like crazy people to stupid people.
pics

Offline Bob_C_CT

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Re: ZXR Front End Replacement
« Reply #27 on: May 02, 2012, 02:40:38 pm »
Sport Rider, yes stock mended fender, rattle canned flat black. Doesn't look half bad with 97 green connie. I believe someone modded a zx6 fender to fit the zrx forks before.
Thanks for the link for the torque specs.
Southern Connecticut.
97 C10,ZRX Front, Meanstreak rim

Offline Slybones

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Re: ZXR Front End Replacement
« Reply #28 on: May 02, 2012, 08:44:23 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

I do  my fork oil every spring. It looks about like this after 1 year. I could only imagine what it might be like for those who hardly ever change it.
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Offline Bob_C_CT

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Re: ZXR Front End Replacement
« Reply #29 on: May 04, 2012, 03:04:22 pm »
Here is some pictures from late last night. Little blurry on some. I thought I had some tubing to bleed brakes but didn't or I would of been trying it out this morning. Still have to put fork brace on and bleed (no more blood on this project) brakes. Have to do something else tonight so will finish tommorow and test ride.

Sport Rider, this is how high the ZRX bars look with the ZRX risers installed.

Can't wait to try out and scrub front tire and hit some twisties. PO of the front end had it on a Connie so I am going to leave settings alone for now and try it out. Back tire looks like it is at least an inch or two higher off the ground on centerstand so it may not get back on the centerstand without riding up on some 2 by 6s.

Going to wear out back tire on stock rim before putting a new 17" on a modded Meanstreak Wheel.

No, the Leroux box was for parts and not for medicinal purposes.
« Last Edit: May 04, 2012, 03:06:48 pm by Bob_C_CT »
Southern Connecticut.
97 C10,ZRX Front, Meanstreak rim

Offline Bob_C_CT

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Re: ZXR Front End Replacement
« Reply #30 on: May 04, 2012, 03:15:50 pm »
Another question I have, the routing of the throtlte cables brings them in from the right handlebar housing then under bottom of ignition switch and then down left side of frame under gas tank and looks like they are going to rub on fairing stay at steering neck when turning the bars. Has anyone rerouted them down the frame at right side of tank? May be too tight of a curve.
Southern Connecticut.
97 C10,ZRX Front, Meanstreak rim

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #31 on: May 04, 2012, 03:30:23 pm »
The fender doesn't look too bad on the bike.

I am not as far along as you.  I'm having minor problems finding a metric drill bit and tap for the ignition switch bolt holes.  I'm going shopping this weekend them.  After that I'll be ready to install.  I've been thinking about the routing of everything as well.  Planned to take some before pics so I can get things in correctly.

Oh...still need to fill fork oil too.  I'll be bleeding the brakes once they are installed.

Offline Bergmen

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Re: ZXR Front End Replacement
« Reply #32 on: May 04, 2012, 05:36:47 pm »
Wow, nice! Very nice!

Awaiting ride report...

Dan
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Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #33 on: May 07, 2012, 01:41:50 am »
Update:  managed to find some time this weekend to get some work done.  Pictures below are of the roughed in top triple.  Note the threads in the bolt holes.  Picked up a tap set at Sears and had some bolts to fit.  A little bit of cleanup and some paint and she'll be good to go.

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #34 on: May 07, 2012, 01:42:29 am »
another pic of the rough finish

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #35 on: May 07, 2012, 01:43:42 am »
ignition switch removed and ready to cut.  The area where the arrow is will have to be cut out to fit around the lock nut on top of the steering stem.

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #36 on: May 07, 2012, 01:45:16 am »
A little love to the ZRX guys.  Received my new fork caps over the weekend.  Their forum is a close rival to ours in having excellent technical content.

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #37 on: May 07, 2012, 01:46:32 am »
Connie looks like something is still missing!

Offline Bob_C_CT

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Re: ZXR Front End Replacement
« Reply #38 on: May 07, 2012, 02:00:46 am »
Got to road test the ZRX front end today. The bars are about an inch or two higher and set back about as much this puts me back in the later model stock seat just about up against the pillion hump which is nice. I didn't have much of a buzz on my stock bars and it seems that these are about the same as far as hand buzz. I had to snug up the steering bearings on the stocker to get rid of deacceleration wobble, I tightened these up ok as I have no wobble and goes from stop to stop with a little less resistance then the really snugged stocker did.

Still have to dry fit the fork brace with new shims I have to make because it will tighten up past what I feel is needed on the individual fork tubes and don't want any fork stiction or interference. The way the brace is manufactured it is adjustable as far as fork to fork distance being made were the actual cross brace connects to the tube clamps.

Riding down at an easy pace on a two lane 40 mph road scrubbing in the new tire I definetly feel a
quicker turn in and a very stable ride  I didn't get to ride any twisties yet.

The front brakes feel superior to the stockers from what I can tell for now because I wasn't too agressive with the new front tire. When I did hit the front brakes a little agressive once towards the end of the ride I got about 50% of the front dive that I was getting from the stock setup. Going over road imperfections was definetly smoother felt like it melted away bumps that I normally would get a little rattle from. I left the settings from PO of the Connie converted ZRX front end had setup. Have to check sag and maybe go for a firmer setup but I do like the cushy feel I'm getting now for slab riding but may not be good for curvys.

I was pressed for time so all I got was about 30 minutes in the saddle.
No slabs yet.   Stopped to check tire pressure at gas station and was going to get fuel but didn't have original key for gas cap, modded triple and ignition from PO, different ignition key for now.

It does feel like a different bike and feels quite nimble will update as soon as I get more ride time.
I want to thank all of you ZRX modifiers that were more than willing to share information from all the hard work you guys have done to make this mod more achievable for weekend wrenchers.
Southern Connecticut.
97 C10,ZRX Front, Meanstreak rim

Offline CRocker

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Re: ZXR Front End Replacement
« Reply #39 on: May 07, 2012, 02:15:26 am »
Connie looks like something is still missing!

Are you doing this with the fairing on?  If so...I'm really impressed!

Looks great so far...

Offline Bob_C_CT

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Re: ZXR Front End Replacement
« Reply #40 on: May 07, 2012, 09:08:06 am »
Working around fairing wasn't as bad as you think. The biggest problem is unplugging and plugging in ignition switch which is located above radiator. The best way I found was to do this before installing lower triple then just leave upper triple in the area of the gas tank.
Southern Connecticut.
97 C10,ZRX Front, Meanstreak rim

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #41 on: May 07, 2012, 02:11:47 pm »
yeah, the fairing hasn't been a problem so far.  I cut the zip tie that was holding the wiring around the frame where the ignition plugs into it.  made it easy to unplug and I'll just zip tie it back when finished.

No work on it this evening as I have to work.  I've gotta finish up the ignition switch and put fork oil in.  Then clean up the upper triple.  then it'll be ready to.  Getting close!  :)
« Last Edit: May 07, 2012, 02:14:50 pm by Sport Rider »

Offline Dave Scott

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Re: ZXR Front End Replacement
« Reply #42 on: May 08, 2012, 02:02:36 pm »
Got the ignition switch housing cut down last night and rough fit top and bottom triple to the bike.  Seems to clear the steering head ok, but need to take a close look at the throttle line clearance to the bottom of the ignition switch.  I picked up fork oil, so after refilling them, I'm going to rough fit everything together and see how it looks with handlebars, controls and everything on it.  However, I'm afraid if I go for a ride on it, I may never take it back apart to make it look pretty with paint.  :)

Offline Bob_C_CT

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Re: ZRX Front End Replacement
« Reply #43 on: May 08, 2012, 07:06:02 pm »
The throttle lines clearance is an issue on mine. It runs under ignition and above fairing mount on steering stem. There is enough room for both to lay flat with about an 3/16" clearance but they do rub along fairing mount when steering stop to stop. There isn't enough room for them to go on top of one another there so I don't think I will have a steering jam problem but they will wear as they slide on fairing mount so I am going to slick them up with some silicone maybe. I should cable tie them above and beyond where the could go below ignition so that they remain as a pair and can't jam steering. Another thought was to reroute under right side of tank instead of left side. Not sure if that radius would be too tight.

Took another ride last night and I am getting used to the faster turn in. Haven't gotten on the slab yet, hope it feels as good at highway+ speed.
Southern Connecticut.
97 C10,ZRX Front, Meanstreak rim

Offline Dave Scott

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Re: ZRX Front End Replacement
« Reply #44 on: May 09, 2012, 01:44:55 pm »
I rough fit the lower and upper triple with the ignition switch, handlebars and controls attached.  The throttle cables seem to be clearing ok, I get a small amount of acceleration when I turn the bars all the way right.  I'll have to do some tinkering with the adjustments.

I noticed a problem with the clutch line having a significant bend clearing the top triple.  Will be even a little worse when I get the fork installed because of the compression preset.  So I loosened the nut and rotated it up some.  I'll test with it that way, but also thought if I installed some risers it would give better clearance for that.  I also considered that a thinner braided steel line would allow more space there too.

Other than that problem, everything else seemed to be working as expected.  I got the fork oil replaced and the forks back together, so tonight I'm going to add that to my rough-fit work.

Pics will follow....

Offline Bob_C_CT

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Re: ZRX Front End Replacement
« Reply #45 on: May 10, 2012, 11:23:54 am »
Make sure you have that little amount of freeplay on the throttle, mine is a little to little and I have to adjust because I am getting a very slight delay getting back to idle when releasing throttle. Slight acceleration when turning bars to the right could also be choke (enricher) cable.

With the risers the clutch cable was ok but I see how the clocking of the hose on the master could be a problem/solution. As I stated earlier with the risers and stock throttle cables the routing brings them right between the ignition and the fairing mount, does yours have enough slack to go forward of the ignition and fairing mount? if so I may need longer cables or reroute.
Southern Connecticut.
97 C10,ZRX Front, Meanstreak rim

Offline Dave Scott

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Re: ZRX Front End Replacement
« Reply #46 on: May 10, 2012, 04:23:27 pm »
No problems with clearance of the throttle cables that I can see.  they seem to wrap around the ignition switch reasonably, but I can see where there are potential rubbing problems on the fairing mount.  I didn't notice prior to removal of stock stuff, but I suspect it's just "normal".  it does not appear to be pinching or anything, so I'll just leave it as is and monitor.  I'll also check the enricher cable for anything there too.

I got the forks, wheels and everything else installed last night as a test fit.  All seemed to install just fine.  One problem I'm seeing is a definite brake drag at the calipers.  I'm going to remove and do a more thorough cleaning of the pistons to see how that does.  Worst case, I suppose I may have to replace them with ones that are working properly.  Cleaning first though, then we'll see.

Oh...the wheel looks TINY!  :D

Offline Dave Scott

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Re: ZRX Front End Replacement
« Reply #47 on: May 14, 2012, 02:45:16 pm »
So, the front end is all on and connected up.  My brakes are not releasing on the rotors, so I am tearing the calipers apart and giving it a sound cleaning.  When I went to replace the brake fluid, I was shocked at how thick the fluid in the reservior was.  I'm sure that's impacting the calipers.  I got the first one apart, cleaned and back together.  I'll do the other tonight.  I decided to go ahead and buy some new pads, so won't get it all buttoned up until late this week when they arrive.  I'm sure glad I've got the Superhawk to keep me occupied!  :)

Offline Bob_C_CT

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Re: ZRX Front End Replacement
« Reply #48 on: May 14, 2012, 04:59:54 pm »
My first run on the highway Sunday. Early morning no traffic and no LEOs. Got speedo up to the century+ mark. Handled it very nice without feeling like I was riding on marbles which was the case with my oem setup.
I did experience a very very slight headshake on deacceleration, might have to tighten up steering stem a bit. I'm going to wait another week or two to let the bearings settle in more as I have to pull the upper triple to get at the adjuster now, I believe. Other than that it felt very confident at speed. Brakes are working like a charm, not as much front end dive as the oem setup and more stopping power feel at the lever. Since there was very little traffic haven't got a feel for how it is going to handle dirty expressway air yet. Except for commuting on nice weather days most of my riding is two lane backroads. Front end lean in is easy, almost effortless and I was worried this was going to affect slab riding but as of now it seems good.

This ZRX setup or something similar is what Kawi should of been putting on 2nd generation Connies to begin with, it did keep the sticker price down though.

I can only imagine how this setup would feel with a 1.2 liter engine, hint, hint, in case someone is thinking of trading his in at dealer for a C14. :rotflmao:

I got my forks, triples, rotors, brakes from a Connie owner that had already machined the upper for the Connie ignition, so that was a time savings, thanks. It was supplied with key so I am a two key owner for now until I see what it takes to grind/mill the stock ignition to fit.

Thanks again to all the trailblazers with their foresight, writeups and advice that have led the way.
Southern Connecticut.
97 C10,ZRX Front, Meanstreak rim

Offline Dave Scott

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Re: ZRX Front End Replacement
« Reply #49 on: May 14, 2012, 05:33:21 pm »
I'll have to take my top triple off again at some point to do finish work and paint, so when I do, I'll snap some pics of the back side of the ignition switch.  I used a grinder and cutting wheel and it was pretty easy.