Zen and the Art of Motorcycle Maintenance: Patience with C14 Forks

 When I was younger I tended to struggle against time, but as I get older I'm finding that if I slow down and let go of that youthful mania I can see things that get missed and this makes me a better mechanic. Taking on the leaky forks on my 2010 Kawasaki Concours 14/1400GTR also seemed like something too complicated to get into in the garage after the much simpler right-way-up forks on the Tiger (which I get in and out of easily).

Like everything else on the Concours, the front forks are complicated. These would be the first USD (upside down) forks I've done after many right way up forks on dirt bikes and the Tiger, so I went looking for how-tos and was met with a wall of incompetence, both in video making and mechanical ineptitude. So bad were some of them that it made the job seem impossible, but it really isn't.

I finally found Coulda Shoulad Woulda's C14 Fork Seal video and it was just the thing. Yes, I'm starting you 25 seconds in because that's one hell of an intro:

Nicely edited and concise (other than that intro), oh that all youtubers took heed. After watching I believed it possible, so out to the garage I went... and was promptly beaten by the bolts on top of the forks which would not move despite a trip to Canadian Tire to buy the long 24mm socket needed to get on them properly. That socket promptly started rounding them. I suspect whoever was in there last didn't believe in torque wrenches.

Everything I needed for the job was $200 taxes
in on Amazon. The tools seem well made and
worked. The fork seal driver also came in
handy when clamping the fork on the bench.

I applied heat and kept at it, but they would not move, so after lots of sweating and swearing I
stepped away and emailed the local Kawasaki dealer, who I tend to stay away from because whenever I contacted them they give the impression that I've interrupted and annoyed them. A terse reply the next morning that was not forthcoming with the details I needed showed that their service department remains firmly of the mindset that they are doing me a favour whenever I pay them exorbitant fees for service. I finally got out of them that it's $375 to service forks out of the bike and they would only use Kawasaki parts so the seals I'd bought for the job I'd have to buy over again at their markup. A conservative estimate for the job would be $500 in service, parts and taxes, but probably more.

That took me back to the garage where, to my astonishment, the tops came off easily after a few sharp taps with a big socket and some more heat applied. If at first you don't succeed, step away and perhaps after cooling down you've already won. As Classic Bike says, 'heat and patience.'

With the tops loose I was off to the races. I applied some
intentionality to my process and decided to do a fork each day after work rather than trying to do them all at once. This paid dividends because the first fork was a learning process, and when I left it for the night I thought it over and the second one went twice as quickly with fewer problems. Taking your time and moving intentionally is an underappreciated skill in our manic, modern world.

The process of dismantling the forks is fairly straightforward, but requires some jiggery pokery around compressing the spring to get to the internals. Here are the order of operations assuming you've already removed the front fender and wheel:

• Loosen the fork tops while they're on the bike! This isn't easy as the handlebars are in the way. I removed them for access. I also found the metal quite soft. I went out and got a long 24mm socket but it made a mess of them. A well placed vice grip while clamped on the bench did the job better.
• Remove the fairing plastic cover over the front wheel
• Undo the plastic cover at the top of the fork tree (three 10mm bolts) and remove the horn as well which is attached to it
• Loosen the lower fork clamps
• Loosen the upper fork clamps
• Slide out the forks (this was also a pain in the ass - I ended up using a long screwdriver to gently open the clamps a bit to let the forks drop

That gets you to the point where you can start working on the forks themselves.

• Undo the loosened fork tops (if you're luckier than me and the cock womble who was in there last didn't tighten them to death)
• Install your fork compression tools. There are holes in the plastic spacer at the top for you to put a rod in and use the axle mount at the bottom for the other rod

It looks complicated but this is just the fork compressor clamp and a bottom rod provided in the Amazon kit being compressed with rachet straps. 

•  With the spring compressed you will see the nut at the bottom that holds on that top piece
• Pull up on the top piece and you should have just enough space to slip the spring holder piece (also in the Amazon kit) in place. This allows you to loosen the bottom nut and spin off the top

• With that off you can release the rachet straps and remove the spring
• Remove the tube from the centre of the unit. It's fragile so put it somewhere safe and then don't forget to reinstall it (don't ask)
• Empty the oil into a container that lets you see how much is in there. Be sure to work the internals to get everything out

The side with the leak (on the right) had less in it, but both were low. There is supposed to be 550ml of oil in each fork. The dark green stuff on the left looked to be completely different to the brown stuff on the left. I'd guess whoever tried to get into these last couldn't get into one of them and just serviced the one they could - which is nuts!

• Separate the outer fork from the inners
• This lets you pop off the outer seal
• The inner is held in by a retaining ring that's easy to pop out
• Ease the fork seal out of the tube (I applied some heat as the old ones were rock hard - this softened them up a bit and made removal easier

• With everything cleaned up, slide the outer seal on the inner fork making sure it's the right way around
• Install the inner seal in the large (upper because these are USD) fork tube. Doing this while it's separated is much easier than trying to hammer it in when they're attached. I had no trouble getting the inner fork tube on once it was installed (the holes in the inner shaft are chamfered so sliding them on is straightforward
• Don't forget to install the retaining ring after you've got the inner seal in (letter side down because these are USD - the 'open' side should be facing the oil).
• Install the inner fork in the outer with new seals
• Put the spring back
• Put the plastic bit on top and rebuild your spring compressor (don't forget the metal cap)
• loosen the nut on the threaded inner rod and use a matching bolt to give you something to pull it up with when you've got it back together
• Compress it all down again with the ratchet straps
• Pull the top using that bolt you put on and slip the metal piece to hold it in place
• Remove the bolt you used to make it reachable and tighten the nut on the inner threaded piece that's held by the tool you slid in to hold it compressed
• Insert that inner rod you put aside earlier (no, really, remember to do that)
• Screw on the fork top piece and tighten to the lower nut to it
• Double check that you've put all the bits back (inner rod, metal cap on top of the plastic top piece)
• Press down on the compressor that's in the holes in the plastic and slip the retaining metal tool out
• Release the rachet straps
• Put 550ml of fork oil in each. I used 15 weight Maxima
• Work the fork to get any bubbles out (I also let them sit overnight to let things settle)
• Spin the outer fork onto the now attached fork top threaded piece
• Reinstall the forks. The lower bolts said 30 Nm but they still gave me headaches when one sheered in the tube. I stepped away and sorted it out the next day when I wasn't annoyed.

This seems like a handful but if you work your way through it one step at a time it all makes sense. The first fork took me a couple of hours to take my time going through. The second one took less than an hour. Once you've done this once you'll feel able to do it again. Give Coulda Shoulda Woulda's video a watch and you'll have what you need to get it done... and be patient!

Yep, that's a broken lower fork clamp bolt sheered off inside the housing. I ended up getting it out by getting needle nose pliers on the end sticking out and spinning it out that way. This job fought me at every step, but it's all back together with matching (clean) oil in both forks and everything one tightened (to spec) not too tight. One tight, not too tight...

When things went wrong (and the did... often) on this job, I got myself to a reasonable stopping point and stepped away for the day. When I came back the seemingly insurmountable problems (stuck fork tops, broken bolt in the lower clamp) all seemed to have answers.

The old seals were rock hard. I'm curious to see how nice the forks feel with the new ones.

Vice grips did a better job on top fork removal than the specially purchased long 24mm socket did. Applying heat was easy in the vice and the seal driver tool was handy for clamping the fork off the bike.

Removing the handlebars didn't help with loosening the tops of the forks. Hat and vice grips on the bench finally did the trick. I'm going to try the handlebards without the bar risers for a while and see if it feels ok.

Sail Away: First Long Ride on The Kawasaki Concours 14

First long ride with Big Blue/Nami-Chan (not sure what its name is yet) today up to Georgian Bay to listen to the water.  For a kid who grew up by the sea living in landlocked Southern Ontario wears on me so sitting by the shore listening to the water lapping on the rocks calms my permanent sense of dislocation.

Thornbury Harbour, Geogian Bay, Ontario - Spherical Image - RICOH THETA

What's the Concours 14 like to ride over distance?  It's a very comfortable long distance machine. Compared to the Tiger it's smoother, significantly less vibey and quieter.  This isn't necessarily a good think because riding a motorbike isn't always about comfort - sometimes you want it to beat the shit out of you.  What is good is that the 1400GTR is a significantly different bike to ride than the old Triumph Tiger, so both fill a different need in the bike stable.

The Tiger (when it works perfectly which isn't often recently) is a capable off roader on trails and fire roads and lets the wind pass through you since it's practically naked, which is both exhausting and exhilarating.  After the long ride today the abilities of the Kawasaki are much more clear.  The only nagging issue is that my backside has gotten used to Corbin seat engineering and the Kawasaki stock saddle just isn't up to the job, but otherwise the bike is a revelation.  Effortlessly quick, smooth and surprisingly agile in the corners, though you can still feel the weight carries but it carries it low.

Windshield down, lots of airflow, a great view
and the bike feels more likes sports-bike.

For the first time I adjusted the X-screen modular MCA Windshield to its maximum length and it did an astonishing job of protecting me at highway speeds.  So much so that I barely closed the Roof helmet on the ride.  The pocket of air it creates is stable and the wind noise so much less that it's just another aspect of this bike that'll let you do long miles without exhausting yourself.

Ergonomically, the windscreen also does something smart for airflow.  If it gets hot you can lower it to the point where it almost vanishes.  This pushes a lot of air through your upper body and supports your chest from leaning on your wrists.  I hadn't put much stock in an adjustable windshield but it not only changes the look of the bike, it also changes its functionality too.  On long rides changes in airflow keep you comfortable and focused.

Windshield up while you're making tracks
on less demanding roads and you're in a
quiet bubble of air that lets you go for miles.

The bike itself seems to manage heat well which the old ZG1000 previous generation Concours 10 I had did not (it used to get stupid hot!).  If stuck in traffic, even over 30°C pavement, the temperature gauge never went above half way and the fans haven't needed to come on yet.  The lack of wind-flow over my legs on hot summer rides may yet be an issue though, the fairings are too good.

The other complexity piece of the C14 that I wasn't sure I was interested in was the digital dash but that too is proving valuable.  I'm no longer guessing what gear I'm in based on revs and road speed so I'm no longer trying to shift into a non-existent 7th gear, which happens often on the Tiger.  Though the 1400GTR revs so low while in 6th/overdrive (3200rpm @ 110kms/hr) that you wouldn't be looking for another gear anyway.

Mileage has been a concern on this smaller-tank/worse mileage than the Tiger bike.  The Kawasaki's 22 litre tank is 2 litres smaller than the Tiger's which also gets 10+ more miles to the gallon.  I'm going to fill up a spare 2 litre gas canister and run the Kawasaki for maximum range a few times to see what this C14 can actually do.  When I fill it up it cheerfully states it'll do 360km to a 22 litre tank which works out to 38.5mpg or 6.1 litres per 100 kms.  The display shows when you're maximizing mileage so a long ride without wringing its neck to see what mileage it can achieve is in order.  If I can get 400kms out of a tank that'll put me up into the mid-40s miles per gallon, which would be a good return on such a heavy, powerful machine.  The range indicator jumps around to the point of being meaningless and then cuts out when the bike gets low and you need it most - not the best user interface there, Kawasaki, but I've heard there may be a wiring hack to stop that from happening.

So, after a 290ish km run up to Georgian Bay and back I'm very happy with the bike's power, which is otherworldly, it's comfort is good but I'm looking at seat improvements.  I've heard other larger riders put peg extenders on so there is a bit less flex in the legs, which might eventually happen.  Many people also put bar risers on them so the bars come towards you a bit more, but I'm finding that I'm able to move myself on the seat to get a more vertical or more sporty riding position depending on what I'm doing, so bar risers aren't on the radar.

I did pick up a spare fuel bottle that fits nicely in the panniers (which take a bit of getting used to for all the keying in and out but are huge and don't affect the bike at speed at all).  Next time I'm on a long ride I'll top the spare bottle up when I top up the bike and then see how far I can push the range.

It was an uneventful ride except for one incident.  Leaving Thornbury harbour the 360 camera fell out of my pocket onto the road.  I pulled over quickly and safely and then ran back to scoop it up off the road.  There was traffic back at the lights in town just starting to move and 3 cyclists riding on the side of the road coming towards me but still some way away.  I ran out to the camera, scooped it up and ran back to the curb and almost took out one of the cyclists who had elected to accelerate towards me rather than giving me space to get off the road.

She yelled, "bike!" and I made a dexterity check that had me dodging around her rather than taking her off the bike.  They kept going but I was left standing there wondering what the thinking was.  You see a guy duck out into the road to pick something up so surely you would ease up a bit and let him do what he needs to do to get out of the way - but not in this case.  From what I've seen of cyclist's approach to sharing the road, I imagine that I'm entirely at fault for that.  It left me shaking my head at their thought processes.

What's a Kawasaki GTR1400/Concours14 like to ride? NUCLEAR SHINKANSEN!

I picked up this Concours14 (or 1400GTR or ZG1400 depending on what market you're in) back in April for $5500CAD.  It had been sitting for some time and was full of spider nests.  I got the safety sorted yesterday and got the bike licensed and on the road today so we're ready to finally make some tracks with this thing.

What's it like to ride?  I've owned more Kawasakis than any other kind of bike and their engines have always been what makes them special, and this bike is no different.  The 1352cc inline four at the heart of the Connie was identical to the ZR1400 hyperbike's motor back in the day, and it shows.

On my first ride I pulled out to pass a truck and it was behind me almost too quickly to process.  I'm coming off owning a late 90s Fireblade so it's not like I'm inexperienced with quick bikes, but the 1400GTR not only has the horsepower but also has the torque to back it up.  Where the 'Blade was staggeringly quick (and light), you had to wind it up to make it go.  It felt like a light but not overpowered machine at sub 6000rpm engine speeds.  At 6k it became seriously quick and if you were brave enough to chase the 13,000rpm redline the bike turned into a total head case.

You don't need to wring the Kawasaki's neck to make astonishingly rapid progress.  It weighs over 100 kilos more than the Fireblade but makes over 30 more horsepowers and pound-feets of torque; it doesn't feel heavy, which is an amazing accomplishment for a bike that can carry over 500lbs, has shaft drive and feels like it's ready for five hundred mile days.

It's not telepathic in corners like the 'Blade was, but that bike's focus was so singular that it made everything else difficult.  The 1400GTR does a good job of cutting up corners, hiding its 300 kilo weight well, but then it can also ride all day, still hit 40mpg and carry two up with luggage.

Ontario makes you buy a vehicle history when you buy a new bike but I don't mind because it offers you insight into the machine's history.  This bike is a 2010 model but it wasn't first licensed for the road until 2014 (!) meaning it's only been rolling for seven years rather than eleven.  The first owner had it two years and then sold it on to the guy I got it from.  He rode it for a couple of years and then parked it after it tipped over on him in a parking lot (hence all the spider nests).

The prolonged park is what shrank the seal in the clutch that I've since replaced.  The drop also stopped the windshield from moving but both things have been solved now and this Concours, with only 32k on the odometer, is finally ready to do what these bikes do best:  make big miles.  One of the guys at our local dealership is a Concours fan and got his over 400,000kms, so these things have staying power as well as horsepower.

I'm looking forward to getting to know this nuclear shinkansen (Kawasaki Heavy Industries makes bullet trains too!) better this summer.