Plugs, Calipers and Frozen Feet

The spark plug (bottom right) is easy to get to once
you remove the distributor caps mounted to the frame.

Yesterday began with a spark plug change on the Concours.  There are two (for lack of a better term) distributor caps (CoG got me sorted, they're coils!) in the shape of cylinders attached to the frame under the fuel tank.  Removing these makes for a fairly straightforward spark plug swap.  Someone had been in here before as one of the distributors wasn't properly attached to the frame (the rear bolt was seized).  With the unit removed it was relatively easy to free everything up in the vice.

I used to be pretty good at gapping plugs by eye, but I hadn't done it in a while.  I got better as I worked through the plugs and the last one only needed a minor adjustment.  The plugs all came out without issue and the new ones went in by hand and then got torqued to spec (14Nm).

The two middle plugs are tucked in behind the radiator and don't collect much road cruft.  The two on the outside
have a tougher life.   Other than being filthy, the plugs didn't show any internal issues.

With the plugs sorted and the under tank electrics cleaned and seated properly, I turned my attention to the rear brake caliper.  I've got a replacement metal brake line, so the old rusty rubber one is going in the spares bin.  The caliper came apart quite easily.  The rear brake on the Concours has always been excellent, but was starting to whine as the pads got thin.  With nothing seized and the main bits just needing a good cleaning, I think this will go back together nicely with new pads and brake lines.  I'd meant to order a caliper rebuild kit from Canada's Motorcycle, but my order got mixed up with a bearing puller I didn't need.  At least now I can tell you how good their return process is.

follow-up:  I requested a return on January 24th and got a shipping label in a reply email a day latter (which I thought was good).  I sent it off that day.  I just got a confirmation email today (Feb 3 - 10 days later) saying it will be another 3-6 days before I see a refund... and I'm charged seven bucks for returning it.  Compared to motorcycle-superstore.com's over the top customer service (immediate, free returns, what can we do to prevent this happening in the future?), I'm left thinking twice about shopping on canadasmotorcycle.ca.


While I'm waiting on the rear caliper rebuild kit I can do the fronts, which is what I'm aiming to get done today.  It's officially frickin cold outside (-20°C overnight, -12°C now), and even with the thick rubber mats I've got down in the garage and the heater going, I still ended up with foot cramps from the cold at the end of three hours in there yesterday.  Winter in Canada can get pretty tedious.  This is one of those days.  If someone called and said they could fly me somewhere warm to ride a bike next weekend, I'd be in heaven.

The two cylindrical distributor caps (COILS! bottom middle &
top right with the spark plug wires coming out of them)
are held down by two bolts.  Once removed from the
frame spark plug access is straight forward.

A longer view of the spark plug.

Naked Concours

The Concours is a naked thing at the moment.  I'm under the fuel tank for the first time since I bought it.  I'm going after the spark plugs, but neither of my imperial spark plug removers would fit.  Kawasaki uses an 18mm metric socket.  Fortunately, Canadian Tire had that very thing in stock.

With the plugs changed it'll be time to start putting it back together.  I'm cleaning electrical terminals and torquing bolts to spec as I go.


The wheels are off, stripped and cleaned and ready for reconditioning at Fireball Coatings.  I'm hoping to get them over there this week.

What twenty year old Concours rims look like after you've had a go at them with SOS pads for an hour.

 
They're off to Fireball for a two stage gold/candy coat finish.  They look better than they have in years already, I can't imagine what they'll look like when I get 'em back!

The stripped bike is letting me get to pretty much everything.  I found the two cut-off gas tank ventilation pipes, which will get properly re-attached again.

Last but not least will be calliper rebuilds and braided metal lines for the rear brake and clutch (which have been waiting until some down time to install - I was loath to do it while I could be out riding).

It will all go back together on new tires and renewed rims ready for the season to begin as soon as the rain washes all the salt and other winter crap off the road.

If I lived somewhere more temperate I'd need two bikes so that I could rotate one out of operation for this kind of work.  Canada obliges by making it miserable outside for four months of the year.

Sense of Satisfaction and some more Concours 3d models

It was a tough week with an empty garage, but the Connie passed safety and it's now licensed and ready to put on some miles, I just have to wait for the snow to stop.  The ride back from shop was -8°C (minus thirteen with the windchill, minus a million when you're riding in it).  With any luck we can get some above zero temperatures soon and I can finally take the big 'un for a long ride.

It was gratifying to have a pro look over the bike and judge it well put together.  Considering all the work I've done on it, it feels like a real validation.

Since I'm with-bike again, I took another run at 3d modelling it...

Kawasaki Concours by timking17 on Sketchfab

Getting to know a very different motorbike

I took the Concours out for a brief ride in the sun this afternoon to get a feel for her.  She's a very different machine than the Ninja.  The carbs are a bit touchy when warming up, but then work in a very satisfying and immediate mechanical way once the bike is at temperature.  It's a much bigger bike too (over two hundred pounds heavier), but surprisingly lithe for its size.

Where the Ninja picks up nicely in lower RPM, the Concours pulls immediately with a much flatter torque curve; the word 'meaty' comes to mind.  The Concours was also surprisingly lively at higher RPMs, pulling hard to the redline.  Not like the Ninja does (which is more like a bull in a China shop), but it still gets you down the road right quick.  The lightness of the internal bits in the Ninja's 649cc parallel twin make it spool up like a turbine.  You can feel the complexity and weight of the Connie's in-line four cylinder as it builds RPM.  Where the Ninja screams like a banshee (and sounds lovely doing it), the Concours has a deeper, more sonorous song, though (and surprising to me because I really love the Ninja howl) equally enticing.  I can see why previous Concours owners have said they've had no trouble keeping up with sports bikes, this is an agile, athletic machine that belies its size.

In corners, especially at speed, the weight of the Connie seems to disappear and I can hit apexes in a similarly precise manner to the much lighter NInja.  With so much torque on hand, you don't need to keep the engine revving hard to get immediate pull out of it.  The Connie will go quickly without appearing to, with the Ninja you've got to keep it on boil to get that astonishing acceleration (as opposed to merely shocking acceleration at lower revs).

Controls wise the Concours is a much more comfortable machine.  The seat is wider and softer, the bike feels more substantial and not so wasp wasted between my knees.  The fairings keep the wind at bay, especially around  your feet.  In the rain your feet are soaked through on the Ninja where they are hanging out in the elements.  Riding in cool weather means thick socks.  I kept bumping my toes against the Connie's lower fairing until I got used to using less toe on the gear change.  Knee bend is still pretty bent, though not nearly as much as the Ninja and with the wider seat didn't seem so intense.

The Connie's gearing is much higher than the Ninja's.   At 120km/hr on the highway you're up around 6000rpm on the Ninja.  I'd guess the Connie would be doing under half that at the same speed.  A more relaxed bike that still has hidden reserves and is light of foot, I'm looking forward to getting to know Connie better.

As I was riding home we fell into a groove, like a horse extending its legs into a comfortable gallop and I realized just how far this bike could take me.  She's been sitting too long and wants to put road behind her.  Instead of wondering when to stop on the Ninja, I'll be wondering how much further I can go on the Concours.

Cycle-Ergo shows me the numbers...

Concours d'Elegance

After a couple of weeks of cleanup and repair, the Concours is back together.  I'm going to take it in for a safety this week and then see about getting it on the road.  I'm waiting on some replacement master cylinder covers and some clutch lever bits.  They should be in mid-week.  I hope to have the safety done by the end of the week.