Concours Cafe Project

[Sport Rider]

now that my C10/sidecar is done, I'm moving on to another project. I have picked up a 1994 Concours 1000 for a wopping $350 and am planning to make a cafe out of it. I've already stripped it down to bare bones and starting to work on repair/replacement to get it running again. I swapped out the front end with my ZRX1100 setup and the rear wheel is my meanstreak milled to work with the rear brake rotor. I've got the carbs off, oil drained and valves adjusted. I'm going to try running pods, however, have been warned that pods on CV carbs don't do well. worst case I'll go back to the OEM air box.

I have the stock ZRX bars on it but may go with a lower set before it's all said and done. the tank is stock, but might end up with something smaller in the end too. I chopped the rear of the seat pan down just for a prototype. trying to find someone that can build a custom seatpan or may have to fab something myself and re-cover it.

still a LONG way to go, but it's the journey, not the destination that counts. :)

[Megadan]

[QUOTE=Sport Rider;296950 I'm going to try running pods, however, have been warned that pods on CV carbs don't do well. [/QUOTE]

They don't tend to do well with pod filters because it changes the pressure ratio between the inlet and "outlet" side of the carburetors, which affects throttle as well as fueling.

The short answer is, it can be done. The long answer is, you may spend a VERY long time getting it to run properly - aka have a good stable idle and proper fueling across all RPM ranges at all throttle positions.

It also really comes down to the carb manufacturer and design. Keihin CV carbs tend to have a lovely combination of both air jets and fuel jets. In the case of my GL1000, each carb had no less than 5 jets to consider - 2 air and 3 fuel. Even changing out to a high flow air filter threw them completely out of whack, and it was a bear to get them working properly again.

This is a really neat project no matter what direction you go. I will definitely be following.

[ben2go]

I'm told velocity stacks help with tuning CV carbs on pods. I have had many problems with my GS running a K&N lunch box filter. It hesitates and stumbles below 3500 rpm. Above 3500, hold on.

[PaiN]

Wow, what a great bike to cafe' out!...I don't think I've seen this done before. I love it and it'll be a ripper when done ;)
I'm excited to watch the project unfold :tup:

[cbrfxr67]

Thanks for posting! Love to see a build come together! SUB'd!

[Sport Rider]

let's see:
- coolant flushed
- sourcing ignition switch. replacement key is 75 plus tax locally. I think I can get one for 50 off ebay
- swapped alternator from another motor only because it was nicer cosmetically.
- installed case clutch cover for cosmetic purposes
- removed petcock and fuel float. internals of tank not good.
- ordered new petcock
- ordered keyless gas cap
- sourcing carbs

I'll get these things wrapped up and then work on starting the bike to be sure it's mechanically sound. after that, tank, seat, headlight, turn signals, hoop for rear, brake light, footpeg, mufflers.

Last but not least, title and tag. :)

[Megadan]

How bad is the inside of the tank? Typical "sat a long time" heavy surface rust? Whatever you do, avoid using fuel tank sealer if you can. Once you use whatever de-rusting method you prefer (Vinegar, muriatic acid, etc) neutralize, rinse, and then fill it up with some MMO and slosh it around really well to help stop flash rusting. Once you drain the MMO back out, put the petcock and fuel float back in and fill it up with treated fuel - I personally love Marine Stabil, but regular Stabil works just as well. Tank sealers end up being more trouble than they are worth, and I have yet to see one that has held up over time.

[Sport Rider]

the potential problem with the tank is some rust bubbling I see around the bottom of the tank. I'm concerned that there are at least pin leaks...if not worse...if/when I'd clean the tank out. from what I have seen so far, it's in the category of "sat a long time heavy surface rust" category. I've used POR-15 in the past with good results, but I'm not keen about the possible pinhole leaks.

[Megadan]

the potential problem with the tank is some rust bubbling I see around the bottom of the tank. I'm concerned that there are at least pin leaks...if not worse...if/when I'd clean the tank out. from what I have seen so far, it's in the category of "sat a long time heavy surface rust" category. I've used POR-15 in the past with good results, but I'm not keen about the possible pinhole leaks.

From my own experience, if it is pinholed by rust, the metal that remains after removing the rust is usually very weak and very thin. A sealant might buy it a little time, but the best thing you could do is find a new tank.

[Sport Rider]

give me some feedback on these prototype photos....

[Megadan]

Purely from an aesthetic point of view, the cowl on the back of the seat in the first picture needs to end just before the rear wheel centerline. Might make the seat a bit cramped though. Other than that, it follows the line and rake of the bike very well.

[cheesy]

Some kid drew on your pics.:hehe:

[Sport Rider]

Purely from an aesthetic point of view, the cowl on the back of the seat in the first picture needs to end just before the rear wheel centerline. Might make the seat a bit cramped though. Other than that, it follows the line and rake of the bike very well.

I agree. I'm hoping I can bring it in a few inches and get the right look without limiting the seating too much.

[Megadan]

I agree. I'm hoping I can bring it in a few inches and get the right look without limiting the seating too much.

I did a quick and dirty edit to what I think would be the best compromise. Moving the rear seat cowl forward what looks to be 3 inches or so to where it begins just before the bolt on the very rear of the subframe. I think that would retain enough seating area to be comfortable while also tightening up the look/visual balance. Realistically you could probably come forward even more than this, but I think this is a practical seat size for most full sized adult males.

[Sport Rider]

I'm going to try to lower the angle of the seat a bit and shorten it too.

for the seat I have my eye on, it's a 16 1/2 inch seat area. I can see 13 or so being fine. that'll save me the length to end at a better looking spot.

[Weldangrind]

One of my favourite design elements on this type of build is the angle of the bum stop. I think it really complements the design to have the bum stop angle match the angle of the rear subframe triangle. I prefer that to a vertical bum stop. Make sense?

[Sport Rider]

One of my favourite design elements on this type of build is the angle of the bum stop. I think it really complements the design to have the bum stop angle match the angle of the rear subframe triangle. I prefer that to a vertical bum stop. Make sense?

I do, and yet that's what I'm struggling with. I'm not looking for a modern sport-bike approach to the rear seat. I've toyed with the idea of chopping that frame section to allow for variation on the angle. that's also the reason for the black out on the lower rear of the tank to artificially create that visual to the eye.

One other thing to keep in mind when looking at those pics....the bike is on the center stand which raises the rear wheel/angle about 2 to 3 inches.

One other thing visually is that the bike is very well endowed at the tank. The rear end needs to be equally plump so as to have some symmetry.

[cbrfxr67]

that's my fav part is that fat tank!

[Weldangrind]

I'm not looking for a modern sport-bike approach to the rear seat.

I'm not recommending a modern sport-bike approach. The bum stop angle I had in mind is similar to this, rather than vertical.

https://www.picclickimg.com/d/l400/pict/231976657885_/Hump-Universal-Cafe-Racer-Seat-Vintage-Saddle-for.jpg

[Sport Rider]

I'm not recommending a modern sport-bike approach. The bum stop angle I had in mind is similar to this, rather than vertical.

https://www.picclickimg.com/d/l400/pict/231976657885_/Hump-Universal-Cafe-Racer-Seat-Vintage-Saddle-for.jpg

I think I get you. the front of the rear hump angled to match the back of the triangle of the lower frame?

[Sport Rider]

thinking ahead. which color do you like?

[cbrfxr67]

yerrrow!

[JerryHawk250]

Orange
http://cdn.shopify.com/s/files/1/0612/3197/files/IMG_0407_26bc0d91-d7e6-4e6a-9ccd-fcf9636740b4_large.jpg?v=1485885788

[Megadan]

THe obvious and ubiquitous choice would be green, but every idiot with a Kawasaki would choose that. Personally, I think yellow is a very overlooked color. A yellow metallic on a white base can look really retro. Or a mustard yellow on a black base for a nice dark tone. Depending on what you like. I have always loved a good solid "mustard" yellow myself. I was going to post this picture, but it is too damn big. http://kickstart.bikeexif.com/wp-content/uploads/2018/01/honda-xr-250-scrambler-7.jpg

Orange
http://cdn.shopify.com/s/files/1/0612/3197/files/IMG_0407_26bc0d91-d7e6-4e6a-9ccd-fcf9636740b4_large.jpg?v=1485885788

Yep, I can agree with Orange too. I have only had two orange pearl metallic Hondas in a row now lol.

[JerryHawk250]

If I had to pick from the three colors I would go with the yellow.

[Weldangrind]

I think I get you. the front of the rear hump angled to match the back of the triangle of the lower frame?

Yes, that's what I'm saying. I think a vertical bum stop disrupts the flow.

[Sport Rider]

I agree with you about the Green, Dan. while an obvious choice for a Kawi, I'm not so sure. I've never owned red. thinking ducati red. Yellow is my favorite. I've had two others in yellow. Might be time for orange. I kinda like that too.

check these out. there's a dark green with gold rims I like a lot.
https://www.flickr.com/photos/avtobus56/sets/72157629739903109/show/?rb=1

[Megadan]

I agree with you about the Green, Dan. while an obvious choice for a Kawi, I'm not so sure. I've never owned red. thinking ducati red. Yellow is my favorite. I've had two others in yellow. Might be time for orange. I kinda like that too.

check these out. there's a dark green with gold rims I like a lot.
https://www.flickr.com/photos/avtobus56/sets/72157629739903109/show/?rb=1

I could go with a dark green. It's a very classy color, and not often seen on modern sport bikes.

I won't argue with Orange either. A large number of my Hondas have been orange, either by choice or coincidence. I painted my GL1000 a Suzuki color called Sunset Copper Pearl. It was a darker orange in the shade, but lit up really brightly in the sun.

https://scontent-dfw5-2.xx.fbcdn.net/v/t1.0-9/18835957_10155436935321992_8239997045702346075_n.j pg?_nc_cat=103&_nc_eui2=AeH-O5jSyhjvIx7iHfVbF8CdnMq7ukVAowQxi_VcE2GH2nlyXdXqvy p4U_PuPwdprDNwSBYaoZeTF1IpqZ4VkBC6QDtASsAlv9-tO9oaZWgnNg&_nc_ht=scontent-dfw5-2.xx&oh=8710ad1124ed77da0bff4ed19357e55a&oe=5CB883BE

[Sport Rider]

I do like that color. it's still a ways off so we'll see when we get closer. for now I gotta get the ignition working and try to get it running. still have a laundry list of things to get done.

I'm going to talk with a local boat shop that does fiberglass work. I'm thinking of using coosa board and fab a fiberglass seat cover for it. I should be able to use the base to attach lights, signals, etc.

[Megadan]

I would be interested to see the results of the coosa board. First time I have even heard of somebody considering that as an option.

[Sport Rider]

I would be interested to see the results of the coosa board. First time I have even heard of somebody considering that as an option.

I've seen some on the web that used wood to build to seat base and then attach the skin to it. I thought about doing that and coating the bottom with something like flex seal to seal it up from water. but then went back to my boating experience and thought about the coosa instead of wood. if it's good enough for a transom, it should be good enough for this. :D

it might depend on how much the guy would want to put together a fiberglass shell for me. it's pretty cheap to get the plastic ones online. but if he does it, he could customize the hump per what Weld was suggesting.

[Weldangrind]

Does coosa board take staples? If so, it would be easy to cover.
Per your boating experience, you could use wood for the seat base and then coat it generously with resin.

[Megadan]

Does coosa board take staples? If so, it would be easy to cover.
Per your boating experience, you could use wood for the seat base and then coat it generously with resin.

Coosa board doesn't retain staples very well. What makes it appealing is it's strength and weight as well as water resistance compared to plywood.

[Sport Rider]

Does coosa board take staples? If so, it would be easy to cover.
Per your boating experience, you could use wood for the seat base and then coat it generously with resin.

should probably explain better. coosa would be the base. about 5/8 thickness. fabricate (or buy) a seat base which would attach to this. maybe glued or something....not sure. then a wood seat pan which is basically rectangular That will have padding and seat cover. probably have bolts out the bottom of that which would go through the board and affix with a nut on the bottom of the coosa bases. not sure how easy it will be to attach brake and turn signals. more research to do. that's whats fun about brainstorming. :)

[Sport Rider]

Haven't been able to get the key for the tank lock, so I decided to order a keyless replacement. in the mean time, I drilled out the lock and removed the cap. Some rust inside, but honestly not as bad as I expected. I'm going to clean and seal it rather than replace. I've used POR 15 before, and will likely use that, but if anyone has experience with some other approach, I'm open to considering other approaches.

[Azhule]

THe obvious and ubiquitous choice would be green, but every idiot with a Kawasaki would choose that.


I was going to say green, but only because it's my favorite color of the three listed... although I could also be one of those "every idiot with a Kawi would choose green"... after all I do own a Green Turtle (KLR 650) :hehe:

[Sport Rider]

another option that is growing on me more and more.

[JerryHawk250]

Yep, Something like this. :tup:
https://bikebrewers.com/wp-content/uploads/2017/03/Kawasaki-KZ440-Cafe-Racer-2-600x344.jpg

[Sport Rider]

something bright. this is hot rod orange. I also like Ford Competition Orange.

[JerryHawk250]

I like it.:tup:

[Sport Rider]

Projects always move too slow....and cost too much! :(

I had a new key made and got my top triple re-installed. I can now turn on the bike, but without a battery, it's somewhat of a futile action.

I pulled the radiator and oil cooler off the front, then removed the headers. that was so I could remove the coolant log on the front of the motor to replace o-ring seals. just precautionary maintenance. also did the same with the rear coolant log which is hidden behind the carbs.

I sourced a right footpeg bracket and peg. got that installed.

I removed the clutch slave cylinder with intentions of rebuilding it. it was froze tighter than dicks hatband. for 18 bucks I bought another used one instead. will install when it gets in. Then I will bleed the clutch as well as front and rear brakes.

I ordered a rebuild kit for the petcock. cheaper than replacing it. once that comes in, I'll get it back together.

Headers are sitting to the side. I have a friend with a 4-into-1 exhaust he's donating to the cause just so he doesn't have to look at them sitting in his shop any more. Only qualifier is I have to use them on the bike. It's a tough choice, but I think I can live with that agreement. :D </sarcasm>

Once the headers arrive....sometime around 2/16, and assuming I have the above items buttoned up, I'll install the headers and then put the radiator back on and properly fill it. I'll swap the tank from my other bike onto this one, and the battery too. Then it's time to see if she'll start.

After I get that far, there's only about a hundred other things to finish. :D

[Megadan]

In my experience it is always the little details that take the most time. Stuff like O=rings, slave cylinders, wiring, etc. It's a lot of work that you can't see in the end, so it makes you feel like you are making no progress.

I try my hardest not to look at my project bikes as 100 things to finish, but individual projects themselves. It allows me to focus more and get it done correctly. I think you are on the right path.

[Sport Rider]

I've been tinkering and thinking about the seat. last night I pulled the cover off the stock seat and chopped things up a bit more. this pic is the stock seat pan with the sides trimmed off to expose the frame. I think I like this better than the other alternatives. the lines don't seem to be too bad with the tank all one color.

[Sport Rider]

today was a day of ups and downs working on an old bike.

got the clutch slave cylinder installed. I had to pump brake fluid through it to get all the crud out of the line. in the end, working good. +1

got the front brakes bled. they were not in such bad shape because they came off the other bike when I switched back to stock. +1

then came the rear brake. couldn't get jack squat to flow through the master cylinder. going to have to find another used one. -1

had to remove the engine cover on the right side because the form-a-gasket was leaking. drained oil, removed, cleaned up, put back together. +1 for job done, -1 because I had to re-do it.

will get the rear brake fixed up and then will have to wait for the new 4-1 headers.

I guess that makes me +1 overall for the day. :)

[cheesy]

Sounds like the new floor project in my wife’s house.*

Can’t relocate the fridge cuz it won’t fit where she wants it to go. +1

Whaddya mean there’s no flooring under the stove? -1

Really? You want the floor vent moved? -1000

Really? You don’t want to do the bedroom floor? +1000

Yeah, I ain’t moving that cabinet from that side of the kitchen to this side. +/-1

Back to our originally scheduled program.

*In my house, the floors are fine.

[Sport Rider]

I hear ya!!!

:D:D:D:D:D

[Sport Rider]

so....today I was able to remove the -1 on the rear brake. the rear master cylinder arrived. I went ahead and got new/used hose and reservoir too. all together, bled out. working like a champ.

I finished buttoning up the engine side cover and added oil back in. no leaks or drips since last night. all good in that department too.

new headers are being picked up in FL by a friend who's bringing them back to NC.

I'm getting more excited to get it running. that'll be a big step!

I'm going to try to get new throttle cables before that though.

[Pathfinders]

I pulled the radiator and oil cooler off the front, then removed the headers. that was so I could remove the coolant log on the front of the motor to replace o-ring seals. just precautionary maintenance. also did the same with the rear coolant log which is hidden behind the carbs.

How bad was this job? I have to do the same for my 2005 plus the t stat gasket. Color of the text is my vote for color of the bike.

Are you planing on bringing the bike to RWTW? I would like to check it out.

Roy

[Sport Rider]

you basically have to clear all the plastics and air/heat pieces under that. once you get it all off, it wasn't too bad. three bolts hold the oil cooler to the bracket. two bolts on each side hold the bracket to the frame. remove the exhaust cans to make it easier to move around the headers. there are a couple bolts on each side of the headers behind the rider footpegs. that was probably the toughest part because of the rust. pulling off the coolant log was easy. getting the rear log off requires pulling the carbs. that's a bit of a test. There are some good instructions for that on the COG website. not sure if you're a member or not. I can help with those if you can't access them.

As for RWTW, not sure if we'll be there or not. I'm planning to be at the spring event in Maggie Valley, but doubt this will be ready by then. will probably have the sidecar there.

[Sport Rider]

making progress. I went and picked up some 4-into-1 headers which a friend in Texas had. he took them to FL to a COG event and a friend here in NC that was going picked them up for me and brought them back.

got them installed on the bike and buttoned up the radiator and oil cooler. put some rattle can orange on the tank just to see what it looked like. still lots to do, but here's the results so far.

I am waiting for new throttle cables to arrive. I'll get them installed and then try to get her running for the first time.

[Pathfinders]

Thanks for the quick reply. You are making great progress with the cafe project. Really starting look like a cafe racer. I have a clapped out 2000 Connie in a storage shed and you are giving me lots of ideas. The last thing I need is another project.

I am a member of COG. We spoke briefly as Dave Despain was pulling into TWOs on a KLR sidecar.

[Sport Rider]

pull that baby out of the shed and let's get started! :)

PM me if you need any other info. I've never done the coolant log rings on my other C10s. I only did these because things were already apart and worth the little bit extra to replace them. I just hope they don't start leaking AFTER my maintenance! :D

[Sport Rider]

anyone good with paint? my paint job on the front fender turned out quite a bit better than the tank. I think the reason is the final coat on the fender was heavier and the paint settled to a smoother finish.

so question is...do I finish sand and buff the tank, or sand down and re-do it?

it's a learning process and I'm absolutely untrained. perhaps untrainable. :D

[Sport Rider]

so, trying a little tinkering. P800 scratch pad to try to even up the paint. then p1500 wet sanding. seems to get it to the point that I'll be able to buff and polish. Still open to any thoughts/ideas.

[JerryHawk250]

Once you get it smoothed out wipe it down with a tack cloth and spray it with a clear coat.

[Megadan]

If it is a single stage paint, then multiple wet sanding stages and a buff as long as the paint isn't too thin. Otherwise, let it cure, sand it back some, and spray it again.

If a 2 stage paint, going with a couple extra coats of clear and a lot of work with wet sanding before the final buff will give a nearly perfect mirror finish regardless of how much orange peel may be on the base coat.

[Sport Rider]

it's a rattle can gloss, so pretty sure that would be considered single stage.

wet sand with the 1500? 2000? I think I have plenty of paint to stand up to the sanding.

[Megadan]

it's a rattle can gloss, so pretty sure that would be considered single stage.

wet sand with the 1500? 2000? I think I have plenty of paint to stand up to the sanding.

I would have to see the finish to really judge where to start, but if the finish is uneven enough I have gone as coarse as 800 grit to knock down the peaks quickly, then 1000, 1500, 2000. I have wet sanded all the way to 3000 grit before, which makes the buffing stage go rather quickly lol.

[Sport Rider]

well, first...keep in mind this is not going to be displayed as a great finish to begin with. it's really me tinkering more than anything. I didn't fix/repair any dents and imperfections, just scratch up the surface and start painting. In time I will have it done professionally (local shop that did my sidecar rig). I buffed the front fender last night and got it to a pretty good shine....all things considered. it's got some imperfections and not a mirror finish by any means. but it'll do for my purposes.

the tank was another issue. I decided to scratch up the surface again and put more paint down. it flowed together a bit better, but going to have to do some real sanding to get it to look better. will do as you suggested. Maybe go back to 60 grit to start. LOL Honestly, I'll probably start at 400 and work my way up. it's that rough.

[Sport Rider]

new throttle cables came in this week, so last night I got them installed. nice to have the throttle snap back now. http://zggtr.org/Smileys/default/cheesy.gif

I got fluids added back in. problems with the ring seals on the rear coolant log. had to remove and install a few times to get it sealed up properly. I realized that I had a split in the ring. fortunately I had another on hand. that was a bit of a pain in the butt cause I put the carbs on before filling, so had to remove them. reinstalled after I was sure there were no leaks.

attached is a current pic. not much looks different except that I have the front fender painted. the tank is still a work in progress. I have further sanding and buffing to complete that. I still have to clean the inside and seal it before it goes into service.

this weekend I'm going to swap over the tank and battery from the 05 and work on getting the motor running. wish me luck! http://zggtr.org/Smileys/default/shocked.gif

http://www.zggtr.org/Themes/default/images/icons/modify_inline.gif http://www.zggtr.org/index.php?action=dlattach;topic=23870.0;attach=306 59;image (http://www.zggtr.org/index.php?action=dlattach;topic=23870.0;attach=306 58;image)

[JerryHawk250]

She's really coming along nicely. :tup: Looks completely different from where you started and in a good way.

[Sport Rider]

it looks pretty good for as far as it's come, but when I look at the list of things still to do, well....still lots to do. Fortunately, none of it is all that hard to get done.

Headlight
front turn signals
instrument cluster
speedo cable
horn
mirrors
clean and seal tank
fuel sensor in tank
seat/base
brake lights
rear turn signals
license bracket
paint rear wheel
finish exhaust
number discs
rear inner fender
new tires

[JerryHawk250]

Man, your pictures are starting to creep me out. I hope that your little one in the door of that last picture because if you look at the bottom picture of post #50 there's a ghost. :wtf:

[Sport Rider]

Man, your pictures are starting to creep me out. I hope that your little one in the door of that last picture because if you look at the bottom picture of post #50 there's a ghost. :wtf:

That's the previous home owner's daughter who died in the house.....

....or it's my granddaughter photobombing. Take your pick.

:D:D:D

[JerryHawk250]

That's the previous home owner's daughter who died in the house.....

....or it's my granddaughter photobombing. Take your pick.

:D:D:D

So who is this little one? Oooooo spooky.:hehe:

[Sport Rider]

or this.....also notice in this picture an addition right behind the front fender when you look through past the forks.

[Sport Rider]

SHE'S ALIVE!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! http://zggtr.org/Smileys/default/grin.gif http://zggtr.org/Smileys/default/grin.gif http://zggtr.org/Smileys/default/grin.gif http://zggtr.org/Smileys/default/grin.gif http://zggtr.org/Smileys/default/grin.gif

Since the tank cleaning/sealing isn't done yet, I swapped the tank off the 05 along with the battery. Put petcock on prime for a minute or two, then back to run. turned on the switch, pulled the enricher, only cranked a short bit before the first burst came out of the pipe. A bit more cranking and coughing and she settled into a high idle. didn't have to run long before I took it off choke and adjusted the idle to a pretty smooth output. I let it sit and run for a good 15 minutes or so as the antifreeze burned off the exhaust wrap. while on the center stand, I ran it through all the gears. everything engaged and shifted normal. then backed her out of the garage and went for a very short run up the street. she didn't seem to hesitate at all, but I didn't have her under much power though. I got up to third and gave her a kick. clutch started slipping. easy enough to replace.

All in all, I'm happy as a pig in mud! 300 bucks, a bit of sweat equity and a few $ more. she runs! I've got about 700 bucks in it now.

[JerryHawk250]

This is getting exciting. :yay:

[Pathfinders]

:tup:Well done sir. One step closer to the next project. They never end.:clap:

[Sport Rider]

to celebrate, I ordered POR 15 components to clean/seal the tank. ordered a fuel float for the tank so I can get it all together when I get it sealed. (already have the petcock rebuilt), ordered some cheap round discs for the number plates. ordered a headlight and mounting brackets to fit the forks.

that'll keep me busy for a few weeks and then I'm going to take it to a local shop to get help with the rear end/seat.

[Sport Rider]

if at first you don't succeed......well.....

I tried some things with the paint on the tank and didn't like it a bit. decided to strip it all down. while uncovered, I did the por 15 cleaner and etcher last night. it's sitting in the house now to get it good and dry before sealing. after sitting overnight it's still damp, so may have to steal the wife's hair dryer and see if I can burn it up. :)

[Sport Rider]

cleaned and sealed the inside of the tank over the weekend. now 4 days curing time before going any further. baby steps. :)

I did order and receive a headlight. looks like it will fit nicely. trying to find mounts at this point. there's a set in Australia that I like.

now looking at gauges.

[Pathfinders]

Gauges we don't need no stinking gauges.:lmao:

[JerryHawk250]

if at first you don't succeed......well.....

I tried some things with the paint on the tank and didn't like it a bit. decided to strip it all down. while uncovered, I did the por 15 cleaner and etcher last night. it's sitting in the house now to get it good and dry before sealing. after sitting overnight it's still damp, so may have to steal the wife's hair dryer and see if I can burn it up. :)

Nice marbling effect. :tup: I'd say spray that with some clear coat and call it done. lol
The tank liner will last a long time when done correct. I've done a couple and gotten over 10 years out of them. I'm sure the newer products work way better than the stuff we had back then.

[Sport Rider]

you might laugh, but I bet someone would pay more bucks for a "custom" paint job. :D

[Megadan]

Wow, I missed a lot on this thread. I am really loving the look of the bike. Not quite Cafe, but not quite sport bike either. It has a very beefy look to it that just kind of works.

I think my own personal change at this point would be to shorten that Jardine can a few inches. Just personal preference though - I don't like big mufflers (as evidenced by the Coffman's on my VFR lol )

[Sport Rider]

I'm feeling the same on all counts Dan. with the ZRX bars on it, it's not a typical cafe look. and of course, the big tank can't be ignored. Long range I might perhaps have someone do some metalwork on the tank, like save the bottom and cut/fab a new top to it that's a bit more cafe-streamlined.

I thought the same on the can too. however, my stopping point is the rear differential, and it seems to fit pretty nicely at this point. The key is, it was free. can't pass that up. :) I might consider cutting it down some, or going some other direction. that'll be down the road after it's street-worthy.

[cbrfxr67]

my .02,...love me a big tank

[Sport Rider]

things feel like they are crawling because I'm waiting for the tank sealer to cure well. However, I got the headlight bracket in the mail, so took a little time to install it. really happy with how well it looks and fits. nice milled part I got out of Australia. Now I gotta wire up the turn signals. One step at a time!

[Sport Rider]

a little cosmetic teaser for everyone.

trust me....still LOTS to do! :)

[JerryHawk250]

Still a lot to do but it's really coming together nicely. I like. :tup:

[Megadan]

Adding the headlight and having it level with the top of the tank really changed the visual impact. It looks a lot less "chunky" visually now.

[Sport Rider]

it wasn't planned. I just threw it on there. :)

[Sport Rider]

gas tank all sealed up and holding fuel as expected. petcock not leaking either. Tank can be permanently put in place. yea!

installed new blinker relay. turn signals now work like a champ.

tried wiring up the tach and idiot lights. epic fail. have the wiring diagram from the bike and the chart from the tach cluster. thought I had it all mapped out. absolutely nothing from the tach. no lights or anything. I even tried just hooking up the positive and negative wires to it. not a blink of light. scratching my head at this point. hair almost gone.

[Sport Rider]

dag nab petcock is still leaking.

@!(%&(%!#@(!#@()%U#%)#!#$^^*!!!!!!!!!!!!!!!!!!!!!!!!!!

[JerryHawk250]

dag nab petcock is still leaking.

@!(%&(%!#@(!#@()%U#%)#!#$^^*!!!!!!!!!!!!!!!!!!!!!!!!!!

Heyyyyy! Watch your language here. >: Hell I'd be cursing too. Just when you thought you had it licked.

[Sport Rider]

I'm realizing that my, um, FRUGAL ways are not always the best. Instead of spending 90 bucks on a new petcock, I decided 15 for a rebuild kit would do the trick. that didn't work cause the original petcock's metal was so corroded that things wouldn't seal. so then I decided that 45 bucks for a used one from ebay would do the trick. another 30 bucks in and I should have just bought the new one to begin with. :(

on top of that, my cheap digital tach/speedo, idiot-light setup is giving me wiring fits. I thought I had all the wiring figured out based on the OEM schematic for the bike. Now why would I expect THAT to work. not even a glimmer from the setup.

Oh...and my turn signals now don't work. I shorted a wire trying to set up the speedo/tach. probably burned out my $2.97 flasher plug.

F it all. Tomorrow I'm taking the sidecar on an Iron Butt ride. That should take my mind off everything.

:(

[Sport Rider]

new petcock arrived. all fuel leakage issues are behind me....knock on wood!

I got a new left switch cluster off ebay. it was very clean and not sun weathered at all. insides looks practically new and very clean. good buy. installed it yesterday.

waiting for a new signal relay which also beeps. while this might be annoying, I do not have a signal indicator on the speedo, so will be a good reminder to cancel signal after the turn.

next is off to an exhaust shop to complete the muffler install. then the seat and rear end. hopefully I can get this in shape for riding by the time the weather turns good.

[Sport Rider]

Celebrating tonight! gonna drink a bunch of beer!!!

after fixing my gas problems, I started having all kinds of electrical problems with the turn signals, then the headlight. started by replacing the switch cluster. no use. thought maybe it was bad (bought a used one), swapped with my other bike. nope. started checking and tracing other connections/wires. then it struck me. let's go back to the root. I swapped out the fuse block with the one on my good C10. ta-da! Problem found! There's a guy that specializes in rebuilding these things for a C10. 80 bucks and no future worries.

I learned my lesson on the petcock problem. not going cheap this time! :D

[JerryHawk250]

Celebrating tonight! gonna drink a bunch of beer!!!

after fixing my gas problems, I started having all kinds of electrical problems with the turn signals, then the headlight. started by replacing the switch cluster. no use. thought maybe it was bad (bought a used one), swapped with my other bike. nope. started checking and tracing other connections/wires. then it struck me. let's go back to the root. I swapped out the fuse block with the one on my good C10. ta-da! Problem found! There's a guy that specializes in rebuilding these things for a C10. 80 bucks and no future worries.

I learned my lesson on the petcock problem. not going cheap this time! :D
Hell I'll drink one with you. Glad you got it figured out.

[Sport Rider]

well, it was another roller-coaster weekend of emotions with the bike. I'm getting too old for this shit! :D

bike mysteriously wouldn't start. therefore the headlight would not come on. I swapped the ignition block and the starter relay from my good C10. no use. more head scratching and a cup of coffee. took apart the switch cluster and tried my best to sand the contact points on the starter button. That didn't seem to work either. decided to swap the other switch cluster with the starter button from the good bike. Another problem solved. also soldered up the signal connections. all good on the front end. bike working as expected. (It's a HUGE plus to have a running bike to swap known good parts off to troubleshoot!)

was looking at my rattle can paint job and noticed a few paint bubbles on each side of the tank which were soft. realized that the tank sealing job didn't do as well as I hoped. I ground off the paint in those areas and applied a couple coats of por15 with a small brush to those areas. waiting for the last treatment to harden now and should be good to go. I had to do this on another area under the tank were the previous owner had used a self-tapping bolt to seal up a hole. When I first saw that one, I did one of those "The Rock" eyebrow looks. LOL

I ordered replacement parts for all the stuff i took off my running C10 to get this one working. I also ordered new clutch plates. What could possibly go wrong with clutch plate replacements, right? :D

[Darkrider]

Up and down and sideways with this thing apparently lol. At what point do you just end up ordering another tank off of ebay? lol

[Sport Rider]

Up and down and sideways with this thing apparently lol. At what point do you just end up ordering another tank off of ebay? lol

when I decide I want it to look nice. :D

Right now it's just a frugal build to get it on the road. in time, if I like it and decide to keep it, I'll look at really cleaning things up and making it look pretty. There's rust spots on the swingarm and a few other places that should get some attention to make it look nice. I'm just painting the back wheel. it really should be powder coated to longevity. The motor needs to be taken apart and parts painted. the finish is kinda rough from the elements. in the end, it will be the attention to detail which will make it stand out. for now, I just wanna ride. :)

[Megadan]

in the end, it will be the attention to detail which will make it stand out. for now, I just wanna ride. :)

This is the most important and difficult part of any project. It's easy to give up on a project when you can't enjoy it. I think you are doing the right thing by simply getting it road worthy and being able to ride it. This will give you a chance to really learn the bike, and you can improve it in stages if you desire to.

[Sport Rider]

clutch upgrade complete. didn't have oil to re-fill, so will stop on the way home from work for that. this evening I should be putting around the neighborhood on it. have to be careful. no rear lights or license on it, so if the po po is around, I'm going to have to play my son-is-a-police-officer card. :D

got all the parts to back fill to my good bike too. it's back to ride worthy again.

[JerryHawk250]

clutch upgrade complete. didn't have oil to re-fill, so will stop on the way home from work for that. this evening I should be putting around the neighborhood on it. have to be careful. no rear lights or license on it, so if the po po is around, I'm going to have to play my son-is-a-police-officer card. :D

got all the parts to back fill to my good bike too. it's back to ride worthy again.

I don't know officer. Light and plate must of fell off. :hehe:

[Sport Rider]

:D :thanks:

[Sport Rider]

I had a HUGE positive breakthrough in my project yesterday. I was able to hunt down and make contact with a guy who had done a C10 cafe build back in about 2013. he had posted some of his work on the COG forum back then and was a COG member at one point. he took the approach of cutting down the swingarm into a single-side swingarm. BTW...I asked him about that last night and he said that was a fail and he went back to a standard swingarm.

anyway...he was able to give me some photos and ideas for the seat and rear end configuration which will be helpful in completing my build. very pleased! :)

attached is the pic of his bike. note the swingarm is back to stock.

[Sport Rider]

it's been a bit of a dry spell lately. I've been doing a lot of staring and thinking about the seat and cowl. I did some trial/error with the current seat pan, and cutting up the original foam. I think I've arrived at a solution though. starts with the frame extension. wish me luck. :)

[Sport Rider]

well...last week ended BADLY. Friday I loaded up the bike to take it to a local muffler shop to get the piece made between the headers and exhaust can. On the way, the trailer somehow came off the hitch. looked back in the mirror and saw the bike swinging violently back and forth. by the time I stopped, it was a gonner. the tank landed square on the tire of the trailer. caved in the side of it. toast. the radiator neck took a serious blow and also split the top hose. that's going to have to be replaced. fortunately the footpeg and bars/controls on that side were saved from problems since the tank and radiator took the brunt of the force.

On a positive note, while at a Concours Owners Group rally over the weekend I happened on a guy who was selling his C10. it has 140k miles and is not running due to carb problems. However, it's in overall good condition. has a tank, upgraded shock, and a few other parts I can use. he wants 500 for it, but I can recoop a lot of that by selling off parts like plastics, footpegs, luggage cases, etc. I think I can earn back enough to offset most if not all of the cost.

this sets me back a couple weeks, at least.

sad part is the muffler shop didn't have pipe to fit. :(

[JerryHawk250]

That ain't worth a poop. :tdown: But on the other hand a good score on a parts bike. :tup:

[cheesy]

Well, :grr:

[JerryHawk250]

Well, :grr: I'm with you on this one. WHERE's THE DANG PICTURES AT??????? :p

[Sport Rider]

if I don't post them, it never happened, right? :D

[JerryHawk250]

I guess it didn't happen. :hmm:
:p

[Sport Rider]

went and picked up this over the weekend. complete bike with 135k miles on the clock. I need a few parts off it for the project, but it's in good shape and lots of extra farkles on it. the carbs are gummed up and the rear hub is leaking. my original plan is to part it out and keep the few things I need. should at least break even.

[JerryHawk250]

Looks like a great part bike. :tup: For having 135,000 miles on it looks to be in great shape.

[Sport Rider]

overall, it is. I'm seriously thinking about just swapping motors from my gold C10 and keeping the silver one. just not sure which is easier, moving all the farkles to the gold one, or swapping my motor into the silver one.

it's been upgraded with bar end weights (for vibration), heated grips, cruise control, and extra shelf setup for the front dash (unique to C10s), highway bars, baker air wings (typically on goldwings), extra fuse block to run accessories, connection for heated gear, Givi trunk plate (that matches mine), quick connect setup for the tank, peg lowers.

decisions, decisions. I still have a cafe bike to get a seat and rear lighting to get done.

[JerryHawk250]

That would be a hard decision to make. Glad it's not me making that decision. lol I know, I'm no help.

[Darkrider]

Neither would i be any help in suggesting the idea of just keeping the silver one as a future project lol

[Sport Rider]

I guess it didn't happen. :hmm:
:p

hopefully this will satisfy your morbid curiosity. :D

[Sport Rider]

it may not look like a big change, but this represents 1 step back and two steps forward. I've swapped out tanks from the parts bike. this one is clean inside and only has a very minor dent outside. once covered in a coat of orange, it'll be a keeper. I also replaced the radiator and hose from the parts bike and she's now back where she was prior. the addition though, if you look close, is the exhaust in it's final location. I got the mid-pipe bent and installed. I just have to put a clamp on the exhaust can to finish it off. That clears the way for the final step...the seat and rear lighting.

[JerryHawk250]

Progress :D Gotta love it.

[Sport Rider]

so....it's been a while. :(

I got a bit sidetracked from working any further on the bike for life events. The lake has been calling the pontoon into service quite a bit, so I've been drinking more beer on the water then turning wrenches.

Other than that, a surprise fix on the "good" bike came up. Did a motorcycle trip up to Woodstock VA to attend an all-day concert. The trip back the next day was uneventful until the last leg when I arrived at home. hit the kill switch and the engine was still cycling. turn kill switch back on...bike starts. turn the key off....cycles....turn key back on, bike runs. "this isn't good". pulled the seat off and unhooked the battery. said F it, I'm going to bed.

Later in the week I had the chance to troubleshoot and discovered my starter solenoid had failed. if you remember, this is one that I replaced as I was putting the cafe back together. lesson learned? don't buy cheap electrical parts for a bike you want to trust. :o

The better part of the story was that on Friday, before the trip up to VA, I decided to start up the project bike and run it up and down the street a few times to give it a little exercise and circulation. When I got back, it was still cooking off some of the antifreeze residue from the pipe wrap, so I let it sit in the driveway and idle for a while to get nice and warm. that's when she puked antifreeze. Shit. pushed it into the garage and said f it to this one too and took off for VA.

The following week after I got the "good" bike working, I turned my attention to troubleshooting.
- got out the trusty wiring diagram to determine how the fan motor works.
- put jumper across the temperature sensor plugs in the radiator. should have kicked fan as it's on an all-time hot circuit. Nada. :(
- unplugged the fan from the wiring harness and plugged in a spare fan that I had laying around. Nada :(
- made a set of mini jumper cables out of plug wire and tested the fan. it runs when connected direct to battery.
- had a spare fan so I tested that too. works.
- tested with volt meter at several points along the circuit. all good voltage readings of 11.9 to 12.0.
- replaced the temp sensor plugs to be sure they were good and had good contact. Nada. :(
- cleaned harness plug and fan plug and put back together. (vinegar/salt method) Nada :(
- removed and replace the wiring harness plug and the fan plug with a new aftermarket set I had laying around. Nada :(

at this point I was....well....frustrated. :cry:

removed battery from cafe bike and put it back on my parts bike. I updated y'all on my new parts bike, right? hooked the spare fan back into the harness on that bike and it worked. :cry: must be in the harness on the bike. :cry:

was posting some details on my Concours group page and one of the guys mentioned testing resistance. hmmmmmmm......

there's a specific in-line fuse that controls the function of the fan. This bike has spent part of it's life sitting out in the wilds. I decided to take that do-dad apart and give it the vinegar/salt cleaning.

You know what happened then????? Wanna guess???????

NADA! >:(>:(>:(

so, once again, I said F it. I just cut the damn thing out of the harness, went to the auto parts store and bought a generic replacement, wired it in (particularly proud that I actually soldered it in rather than just twist together and electrical tape it), heat shrink wrap to seal it up.

TADA!!!! The magic happened! :yay::yay::yay:

took the jumper bypass off the temperature sensor (so the damn fan would stop), got the bike up and running and let her cook until I saw the fan motor kick on and off a few time. No coolant puke!

Now...back to our regularly scheduled programming.

:hi::hi::hi:

[JerryHawk250]

Man, I started reading and by the time I was half way through it I would of said grab some beer and head back out to the party barge on the lake. lol Happy to see something went halfway right.

[Sport Rider]

did I happen to mention how much I DESPISE electrical problems?

:tdown:
:grr:
>:(
>:

[GronkFries]

I'm realizing that my, um, FRUGAL ways are not always the best. Instead of spending 90 bucks on a new petcock, I decided 15 for a rebuild kit would do the trick. that didn't work cause the original petcock's metal was so corroded that things wouldn't seal. so then I decided that 45 bucks for a used one from ebay would do the trick. another 30 bucks in and I should have just bought the new one to begin with.
:(

I briskly glided through this thread - Very cool project! Had this problem on one of my Hondas and had to chuckle when I read it. I think I had at least $400 in trying to save an old tank and petcock with epoxy, rebuild kits, brazing, you name it. Ended up buying a used $165 tank and $105 brand new OEM honda petcock that I had always seen for sale and resisted vehemently. Thought "those thievin' bastards!" Now I have $670 in something that would cost much less having had understood the concept of paying a higher price for hard to find excellent condition parts.

Looking forward to seeing the finished product!

[Weldangrind]

Any time you go from NADA to TADA, call it a win.

[JerryHawk250]

Sooooo….. any updates????

[Sport Rider]

not a dam thing. :(

life is getting in the way. trip to Maine. fixing house to put it on the market. weekends on the boat as often as we get a chance. various concerts from Peter Frampton to Luke Bryan to Guns n Roses (last night). I was just thinking the other day that this might be a two-winter project.

I was having a problem with the front brakes sticking. I know the calipers are good cause I rebuilt them not long ago. I suspect it's the master cylinder. I have a spare, so planning to swap. I thought I might as well replace the brake lines while I'm at it. I ordered some. first color choice was orange. second color choice was black. third color choice was basic silver. They sent me blue. go figure.....

[Megadan]

Live life and do the projects when you have down time. It will get done before you know it.

[cheesy]

Sounds like you have a blocked bleed hole in the master cylinder. Time to dismantle and clean.

Time spent on the boat and at concerts isn’t life getting in the way, it’s having a life.

[Sport Rider]

our LATE summer down here isn't helping matters either. Late September and still 93? :o

[JerryHawk250]

Same here. Breaking record highs for a week or two.

[Megadan]

our LATE summer down here isn't helping matters either. Late September and still 93? :o

Our late summer is doing it's normal thing. Temps are bouncing all over the place from day to day - 90 to 70 to 85 to 46 to 75 to 90 to 60. Mix that with rain, sun, rain, sun, rain, rain, sun/rain.

Makes riding here an entertaining experience.

[Sport Rider]

send the rain here. we haven't seen any in well over 2 weeks now. plus hopefully it'll lower the temps!

[JerryHawk250]

We only got .02" of rain for September. The grass is starting to turn a nice shade of greenish brown.

[Sport Rider]

my back yard where the dogs run has a nice tan cloud around it all the time. :D

[Sport Rider]

well, since it actually rained yesterday, it was perfect weather to work on bikes in the garage. I decided to go ahead and install the blue brake lines I ordered. Maybe I'll paint the bike blue. who knows. it's actually an interesting contrast with the orange.

Regardless, that job is done. I'm going to get it started up and run it a bit on the street to give it some exercise. Next step will be to take it to the show down in Gastonia to see what they will charge me to work up the seat and rear end. Preparing myself for sticker shock.

I also managed to pull the carbs out of the daily C10 driver. it had dirt and was only idling on 3 cylinders. pulled each bowl off, both pilot and main removed, gently blew out the circuits. all back together and running normal again. I installed a fuel filter to prevent more dirt getting in. will have to empty and clean out the tank as soon as I run the gas out of it.

Productive weekend. :)

[Sport Rider]

a monumental step forward happened yesterday. I asked a friend of mine to help me bend some tube to make the rounded back end so I could start thinking about the cowl design. he shot me an address and said he was heading that way to turn the heat on. When I arrived, he was there but also a surprise guest. The shop he told me to meet him at belongs to Ron Hornaday Jr. Yep...the NASCAR Ron Hornaday Jr. I was surprised to put it mildly. Ron took a break from a racing frame that he was putting together and we all pretty much tore into my bike. Ideas were flowing and at the end of the day, the picture is the result. We were actually there for about 8 hours. I keep pinching myself that I had all this great help!

Ron had some cheap rattle can paint sitting around his shop. So we put a quick coat of black on the frame parts and he decided the gold on the rear cowl would match the tank. well....almost. :D

BTW....his shop? about a 40 x 60 building. early 70s dodge charger was up on a lift under a tarp. below that was a modded frame from a Chevy Luv. Beside that was a dirt late model track car up on a lift as well. Then there was the body of the Chevy Luv that he's working on. Next to that was his frame station which had an almost complete racing frame on it. To the left coming around the shop were two other dirt track cars under covers. one he was rebuilding for another driver, and one which is his son-in-law's who races regularly (it's off season, of course).

there's still a bit to do, but we've got everything roughed in. Ron said to bring it back when I get closer to the finished product and we'd make some better parts, particularly the fender protection underneath.

#cloudnine

[Sport Rider]

quick rattlecan color match. it'll be different in the end, but this will be good enough to get it running.

[JerryHawk250]

Looking good! Lets see some fly by videos. :D

[Sport Rider]

look close....no carbs yet. it would only be a push by. :D

[JerryHawk250]

look close....no carbs yet. it would only be a push by. :D

:lmao: I thought the was than new fangled EFI system you installed.

[Sport Rider]

the latest pictorial installment. I purchased a license plate bracket with tail light, brake light and plate light integrated. got that installed and wired up along with the turn signals. put the battery back in the bike to test everything out. works like a champ. for being cheap, it looks like it's decent.

just waiting for carbs to get it running and on the road. Still have the seat to cover, but my butt will hold that down for now. :)

[Weldangrind]

The bike looks just mean from that angle.

[Sport Rider]

I'm still waiting for my carbs to come back, but still making progress. in fact, once I get the carbs in, it will be ready for the road. It will need new tires, but the ones that are on it are ok for test rides. For now....two new additions!

[herbie]

Nice, looks like your getting close Dave! Did you send the carb's off to Steve in sunny Florida?

[Sport Rider]

Nice, looks like your getting close Dave! Did you send the carb's off to Steve in sunny Florida?

Yep. it's been a waiting game though. Steve has had a pretty bad dose of the flu going around, so his work has backed up on him a bit.

[herbie]

Yeah, I read where he was pretty sick and getting backed up on his work. I'm sure it's worth the wait though, you can't beat his work.
I miss my old C10, why is it every time you sell a bike you end up missing it? It's pretty cool seeing one over here on Chinariders, looks like you are making this one your own for sure.

[JerryHawk250]

She's looking real nice. :tup:

[AJboughtamoto]

Wow looks great! I've owned a couple connie's great bikes. Been thinking about making the Voyager into a cafe.

[Sport Rider]

Wow looks great! I've owned a couple connie's great bikes. Been thinking about making the Voyager into a cafe.

That might actually be a bigger pig than my C10. :D

after getting this done and sitting on it, it's a long reach to the bars. once I lower them it will feel more so. I'm thinking that it may work well with a long and more narrow cafe style tank. the thing I can't much get away from is how big the motor is. but hey...that's the platform I started with. for now, I'll just be happy to be riding it!

[AJboughtamoto]

Haha yeah she's a big girl. The engine is wonderful though. I've never seen one done, I imagine she would be a beast with a few hundred pounds worth of fairings and luggage removed.

[herbie]

Haha yeah she's a big girl. The engine is wonderful though. I've never seen one done, I imagine she would be a beast with a few hundred pounds worth of fairings and luggage removed.

That would be a cool and unique project AJ! If you go that route be sure and snap some pics for us. I've heard nothing but good things about the Voyager engine.

[Sport Rider]

That might actually be a bigger pig than my C10. :D

after getting this done and sitting on it, it's a long reach to the bars. once I lower them it will feel more so. I'm thinking that it may work well with a long and more narrow cafe style tank. the thing I can't much get away from is how big the motor is. but hey...that's the platform I started with. for now, I'll just be happy to be riding it!

I guess I shouldn't be, but I'm surprised there are actually a few photos out on the web for a Voyager conversion. It looks nice too! it also gave me an idea about an alternative tank idea!

[AJboughtamoto]

I guess I shouldn't be, but I'm surprised there are actually a few photos out on the web for a Voyager conversion. It looks nice too! it also gave me an idea about an alternative tank idea!

Links? Ive never seen one done.

[Sport Rider]

both these showed on pinterest....

[AJboughtamoto]

Dang! Those look badass!

[roundhouse]

Dude I just found this thread! COOL!!!!!!!!!!!!!!!

[cheesy]

Not a fan of Cafe' style bikes but that gray one is sharp.

[Sport Rider]

Not a fan of Cafe' style bikes but that gray one is sharp.

yeah, but not as sharp as mine. :D:D:D

[Sport Rider]

Made some killer progress this week. Probably the biggest jump forward since I started the build. It really is impressive to see how this addition has transformed the project so significantly. Just look at those babies peeking out underneath the headlight. Awesome!

I know you're all are stunned and speechless.

:thanks:

[JerryHawk250]

:tup: I'm speechless. Lol nice!

[Sport Rider]

Had to have them to pass inspection. I got word my carbs are in progress, so I'm looking forward to hearing it run and being able to get it on the street. I still have to replace tires before the inspection though. not a biggie, just $$$.

[Sport Rider]

last last week I got my carbs back. Saturday I got them installed. she started up and ran great. Now for the problem. Clutch plates slipping TERRIBLY bad! change oil. better, but still slipping under heavier power. I had replaced the friction plates last summer when I was freshening up things. I don't recall I did the springs though. Have some on order now and will have to pop off the side case when they come in. I was able to ride it around the block a bit. it ran good. just couldn't drop the hammer like I wanted to. :)

[Sport Rider]

late last week I got all the clutch parts I needed to get things fixed up. got it all put back together but had to also replace the master and slave cylinders to get things right. it still needs some bleeding to be "right", but it's working enough for a couple shakedown runs.

The first run I stalled the bike at a stop and it was slow to turn over. battery problem. I headed back to the house for some diagnosis. turns out it was a broken wire in behind the battery box. appears it was just old and brittle. replaced than and headed back out for another shakedown.

second shakedown the front turn signals and horns ended up not working. likely some loose wires. I didn't baby it and the exhaust note was sweet. nice growl down low and she screamed at the top of her lungs up high. hit 100 in 4th gear and still pulling nicely. Stopped to get gas as well. started right up afterwards.

I am DEFINITELY going to get a ticket on this thing. :D

still have a few more odds and ends to button up, but overall, she's about ready for inspection and tags to be legal.

[Sport Rider]

Christmas!

[Sport Rider]

a little bit of prep work before the new shoes go on....

[JerryHawk250]

That's right, you don't put on a new pair of shoes with old socks. lol :tup: Going to look nice.

[herbie]

After all this work and now your almost done, so what are you going to do with all that extra time? :lmao:

Looks nice by the way, I like the big headlight, fits well with the big bike.

[Sport Rider]

probably ride it for a while, then sell it and start on the next one. a bobber will probably be next.

[Sport Rider]

so, after a couple rounds of bleeding the lines, the clutch seems to be working well. I also got the tires on after the above prettying up of the rims. I also grabbed the progressive shock off the parts bike and put it on the project bike as well. I also had to replace the turn signals because I blew out both bulbs and since they were not LED, I decided to get another set.

With all the done, I got a chance to take it out for a good ride this weekend. A friend of mine is just learning to ride. he was anxious to get out and get some practice, so I took the project bike out for a slow-paced ride with him. we were out a couple hours and did about 50 to 60 miles. other than a wiring problem with the horns, it ran fine and didn't have any problems at all.

Very happy with the progress so far and once I get the horns sorted out, it will be ready for inspection and licensing.

yea!!!

[Sport Rider]

so....after the long ride I posted above, I discovered that my front turn signals were out as well as my low beam. both bulbs on the signals fried as did my low beam on the headlight. I found a broken wire in the headlight bucket. I also decided to other different turn signals that were LED. after fixing those, I got a replacement horn. both horns are now hooked up and honking like goosed geese. I think I'm now ready for inspection, but the weather has turned sucky. no win. :(

[Sport Rider]

I had a chance to get away from work for a while on Friday and take the bike up to get inspected. then about 2 hours of riding. just need to get insurance set up and I can go get a tag for it. Already thinking of the next project. I'm going to convert something into a bobber.

[Sport Rider]

one of the guys on the ADV site turned me onto a direct fit tank from a 84-86 900 Ninja.

skinny....fat....

I have a new paint scheme!!!

[Sport Rider]

a little different view....

[Sport Rider]

the new look....

[Sport Rider]

More updates on the project. I rebuilt the seat to fit the contour of the back end of the tank. it was a smaller/narrower seat at the tank. I ended up cutting up the two seat pans and then grafting them together to make one.

[Sport Rider]

I also installed clip on bars and got a left footpeg from a C14. since it's straight and does not have a drop down/forward like the stock C10 footpeg, it effectively gives me a rearset of about 1 up and 1 back. it fit right up to the stock bracket. I'm going to do the same on the right.

[JerryHawk250]

I like the new tank more. :tup:

[Sport Rider]

it definitely doesn't feel as fat. :)

[Sport Rider]

converted to silver!

[JerryHawk250]

I like the silver much better. :tup: Looks like a completely different bike.

[bmw111]

Cool. Every season I see lots of Concours for sale in my area, some quite nice. I'm always tempted because they're such a great bike -- now I'll be even more tempted when I see them for sale.


Thanks!

[Sport Rider]

Cool. Every season I see lots of Concours for sale in my area, some quite nice. I'm always tempted because they're such a great bike -- now I'll be even more tempted when I see them for sale.

Thanks!

I would struggle doing this to a "nice" example. Mine was in pretty poor shape. I only paid $350 for it. that tells you the condition. my first step was changing all fluids and doing all the adjustments. from there, the goal was to see if it would run. after that, the party started. I will say it would have been far easier to start with one in better condition. if you were able to find one that had damaged plastics cheap, that'd be a good starting point.

[bmw111]

What do you think of the ride itself? Does it bring back any memories of the good old days, or just feel big and heavy? I think with that Ninja fuel tank it really looks good. Nice job.

[Sport Rider]

I have a ZRX1100 front end, so the ride of that is far different from the stock C10. I also have a progressive aftermarket shock in the back, which is FAR superior to any other shock I run. (stock, ZZR1200 or C14). The ride is a bit edgy, but that's really what I want for this style of bike/riding. Handling with the ZRX front end is different from the C10 anyway. while it's a little heavy at very slow speeds, at high speeds, it feels very solid. The bike overall is not one to flick about, but to simply provide inputs and let it run it's line. it doesn't feel heavy, just very solid. no twitching or nervousness from the front end. I have not yet had much seat time with the clip on bars. I'll know more after I get a chance to drag my knee pucks a bit.

[Sport Rider]

Here's kind of a final recap for everyone. at this point I don't have any other significant ideas or changes. I'm going to take some time to just ride and enjoy it for a while. I may come back to some things like paint, pod filters, battery and electrical relocation. for now, just social distancing!

1998 Kawasaki Concours. front end is from a 1999 ZRX1100. clip on bars, mirrors, headlight and speedo are aftermarket. Tank is from a 1985 ZX900R. Rear wheel is from a 2002 Kawasaki Meanstreak. rear brake rotor from Nomad 1500. Footpegs are from a Concours 14. Seat is a ZX900r grafted to the stock 98 Concours seat pan with a custom cover. Rear end and cowl are custom built. exhaust is a custom 4-2-1.

[JerryHawk250]

I would say it's done and ride the hell out of it till it's to cold to ride then worry about the mods. :tup:

[bmw111]

Nice. I bet not many people correctly guess the donor bike.

[Sport Rider]

had a guy role up beside me in a truck yesterday. Asked me what year it was. I thought for a sec and said 85, 98, 99, 03, 05, and 08. :D

[cheesy]

Just like Johnny Cash, One Piece at a Time.

[Sport Rider]

I am now officially tagged, titled and licensed to get out on the streets and act like a squid!!!