Motorcycle Carburetor Rebuild Part Eleventy-Seven (airbox boots)

The carburetor rebuild grinds on.  It took the better part of a week to get the airbox boots in, and when I opened the bag they came in I'd been charged for four but only got three.  I tried contacting Two Wheel Motorsports to ask if the fourth boot was sitting around there, but they didn't get back to me.  

The Concours uses two types of boots to connect the carbs to the airbox and one of the old ones still had pretty good flexibility in it, so I used the three new ones and the best of the old ones.

I tried for the better part of two hours to get the carbs mated to the airbox properly with the stiff, old airbox boots without success.  With my home-made hooked screwdriver (to slip the boots onto the intakes) it took about ten minutes of adjusting to get a good seal on all four carbs.  If you're doing an old carb rebuild, buy some new airbox boots, it'll save you a  lot of frustration and swearing.

The old airbox boots look rough, but the real issue is that the rubber has hardened over time and no amount of heat will soften them up.  The new boots were supple and easily went on the carb air intakes with minimal fuss and bother.

I pay for four and get three.  Fortunately one of the old ones was still pretty supple so I could reuse it.

Ten minutes and the carbs are back in place.  Get new airbox boots if you're rebuilding an old carb!

Evolution of Motorcycle Ownership and a Triumphant Return

Back in August of 2014 I wanted to take a more active role in my motorcycle maintenance.  At that point I'd been riding for just over a year on my first bike, a very dependable 2007 Kawasaki Ninja 650r.  I learned a lot on that bike, but it was a turn-key experience, the bike needed very little in the way of maintenance.   

The Ninja went from flat black to metallic blue and orange.  It was the last bike I rode that people commented on (I'd often get a thumbs up or have someone stop and chat in a parking lot about how nice the bike looked, which was satisfying as I'd been instrumental in restoring it from angry-young-man flat black).  The Ninja was, without a doubt, a good introduction to motorcycling, and was the king of the roost for my first two seasons.

As a first bike, the Ninja led the way both on the road and at the top of the blog.

I wanted my next bike to be one that ran because of my mechanical skills rather than one that didn't need them.  I found a 1994 Kawasaki Concours sitting in some long grass about twenty minutes away.  I quickly discovered that sense of satisfaction I was looking for.  The Concours was an eager patient who rewarded a winter of mechanical work with a rock solid five thousand miles of riding the next summer.

The Concours has offered some memorable rides, especially looping Georgian Bay and riding on the Indianapolis Motor Speedway.  For a bike that looked like it was being permanently parked with only 25k on it, suddenly it was back in the game, going places other bikes only dream of.

That busy season of long rides took its toll on the Concours though.  It isn't a spring chicken and after having spent the better part of two years parked before I got to it many of the soft parts on the bike were getting brittle.  I parked the Concours early and began winter maintenance knowing that the bearings and brakes both needed attention only to miss out on a late season warm spell at the end of November and into December.  I took that one on the nose figuring that's what happens when you ride an old bike as your daily rider.

The header on this blog for the past eighteen months, but running a twenty-two year old bike as your daily rider
makes for frustrations.  Time to be less sentimental and more rational in how I manage my stable.

That summer we were touring on the Concours I picked up a KLX250 to experience off road riding, but doubling insurance costs for a bike that I only managed to get out on a handful of times didn't feel very efficient.  That I struggled to keep up with traffic on it didn't support the way I like to ride.  Motorcycles are open and unprotected, but they are also agile and powerful enough to get out of a tight squeeze - except when they aren't.  The Concours was always there and the preferred ride, owning the road when I was on it.  When I went out with my co-rider he also loved the big red Connie, not so much the rock hard, under-powered KLX (he only ever rode on it once for less than five minutes).

Over the winter I put some money into the Concours, doing up the rims and getting new tires.  With the rims off I also did the bearings and brakes.  As everything came back together again, suddenly the carburetors weren't cooperating.  They're since being rebuilt and the bike should be back together again this weekend, but instead of always being there, suddenly the Concours wasn't.  As winter receded I could hear other bikes growling down the road, but I was grounded (again), even though I was paying insurance on two machines and longing to get back out on the road after an always too long Canadian winter.

The KLX was the first to go.  I'd never really bonded with it and, even though I always figured I'd run this blog with my most recent bike in the graphic at the top, the KLX never made it there; it never felt like the main focus of my motorcycling.  In the same week my son's never-ridden PW-80 got sold, and suddenly I had some money aside.

Ready to go with a new header, but it never took.

As days of potential riding keep ticking by and the carburetor work drags on, the Concours started to feel like an expensive anchor rather than the wings of freedom.  I had a long talk with my wife about it.  She asked why I don't unload it and get something dependable.  Keep the old XS1100 for that sense of mechanical satisfaction, but have a bike that's ready to ride.  I think sentiment was paralyzing me.  Hearing a rational point of view with some perspective really helped.

Many moons ago,
a pre-digital Triumph

With cash in an envelope I began looking around.  Before Easter we weathered an ice storm, but only two days later it was suddenly in the teens Celsius and bikes could be heard thundering down the road.  Meanwhile I was waiting for yet more parts for the Concours.  Online I was looking at sensible all purpose bikes that would fit a big guy.  Vstroms and Versys (Versi?) came and went, but they felt like a generic (they are quite common) compromise, I wasn't excited about buying one.

Since I started riding I've been on Triumph Canada's email list even though I've never come close to owning one (out of my league price-wise, no one else I know had one, no local dealer... pick your reason).  As a misguided teenager I purchased an utterly useless Triumph Spitfire, and in spite of that misery I've always had a soft spot for the brand (your adolescent brain makes your teenage experiences sparkle with emotion even when you're older, that's why we all still listen to the music from our teens).

A Tiger?  On Kijiji?  Must have
escaped from a zoo!

While trawling around on Kijiji looking at hordes of generic, look-a-like adventure bikes I came across an actual Tiger.  It was (as are all Triumphs I've mooned over) too expensive for me, but that Lucifer Orange (!) paint haunted me.

Another rare warm afternoon wafted by with the sounds of motorcycles on the road so I thought, what the hell, and emailed the owner.  He'd been sitting on the bike for the better part of two months with no calls.  He was going down to the Triumph dealer on Thursday to trade it in on a new Street Triple and knew he was going to get caned by them on the trade in price.  He emailed me back and said if I had three quarters of what he'd been asking, he'd rather sell it to me than give the dealer the satisfaction.  Suddenly this fantastic looking machine was plausible.

The garage is 100% more functional than it was last week,
100% more glamorous too!

A trip up to Ontario's West Coast and I got to meet a nice young man who was a recent UK immigrant and a nuclear operator at the Bruce Plant.  The bike was as advertised (well looked after, second owner, some minor cosmetic imperfections), and suddenly I owned a freaking 2003 Triumph Tiger 955i!

Most used bikes offer up some surprises when you first get them, and they usually aren't nice surprises.  The Ninja arrived with wonky handlebars the previous owner told me nothing about.  The XS1100 arrived with no valid ownership, something the previous owner failed to mention during the sale.  So far the Tiger has had nice surprises.  It arrived with a Triumph branded tank bag specific to the bike.  Oh, by the way, the previous owner said, the first owner put a Powercommander on it, and then he handed me the USB cable and software for it.  It had also been safetied in October, less than two hundred kilometres ago (paperwork included), so while I didn't buy it safetied, it shouldn't be difficult to do.  The bike has fifty thousand kilometres on it, but I then discovered that the first owner did two extended trips to Calgary and back (10k+ kms each time) - so even though it's got some miles on it, many of them are from long trips that produce minimal engine wear.  After giving it a clean the bike has no wonky bits under the seats or anywhere else.  I cannot wait to get riding it.

So, here I am at the beginning of a new era with my first European bike.  I've finally picked up a Triumph from the other side of the family tree (the bike and automobile manufacturing components of Triumph split in 1936), and I've got a bike I'm emotionally engaged with.  It might even be love!  Like the BMW I rented in Victoria, the controls seem to fit my hands and feet without feeling cramped and the riding position is wonderfully neutral.  When I'm in the saddle my feet are flat on the ground - just. Best of all, I don't look like a circus bear on a tricycle on it.


With the Concours officially decommissioned and awaiting (what are hopefully) the last parts it needs before being road worthy again, it's time to update the blog header:

What's next?  The Concours will be sold with only a modicum of sentiment, the Tiger will be safetied and on the road (it cost $90 a year more than the Concours to insure), and I'll enjoy having an operational, trustworthy machine made in the same place I was with lots of life left in it.  The fact that it was getting me thumbs up and one guy stopping to say what a nice bike it was when it was on the trailer on the way home doesn't hurt either.  Riding a tiger has a certain magic to it.

When I want to turn a wrench I'll work on the XS, getting it rolling again for the first time in years.  I'll get the ownership sorted on it (affidavits are required!) and eventually sell it without losing a penny, and then I'll go looking for my next project bike.  Maybe a scrambler Versys, maybe an old Interceptor, maybe something I haven't thought of yet.

Time for some unbridled Tiger enthusiasm!

Tyger Tyger, burning bright, 
In the forests of the night; 
What immortal hand or eye, 
Could frame thy fearful symmetry?

In what distant deeps or skies. 
Burnt the fire of thine eyes?
On what wings dare he aspire?
What the hand, dare seize the fire?

And what shoulder, & what art,
Could twist the sinews of thy heart?
And when thy heart began to beat,
What dread hand? & what dread feet?

What the hammer? what the chain, 
In what furnace was thy brain?
What the anvil? what dread grasp, 
Dare its deadly terrors clasp! 

When the stars threw down their spears 
And water'd heaven with their tears: 
Did he smile his work to see?
Did he who made the Lamb make thee?

Tyger Tyger burning bright, 
In the forests of the night: 
What immortal hand or eye,
Dare frame thy fearful symmetry?

Concours Carburetors: Prepping for rebuild

There are three rails holding the four carbs together on a Kawasaki ZG1000 Concours.  Two of them are structural and the other one holds the choke mechanism in place.  Taking them off a twenty two year old carburetor can be trying.  I ended up having to cut a line in one of the retaining bolts and put some heat on it to get it to let go, but all three pieces are out now.

With the four carbs separated I'm now waiting on the rebuild kits.  When they arrive I'll rebuild each carb one at a time (so I don't mix up parts).  All four carbs are cleaned up (a touch of carb cleaner and a toothbrush got 22 years of grime off) and awaiting some new gaskets, float adjusting and rebuilding.  While in there I'll make sure the needles are in good shape and everything has the right geometry.

The first one will be exploratory and slow, by the fourth one I'll be able to rebuild these things in my sleep!

The four carbs separated and cleaned.   Taking a twenty two year old carb apart takes some patience, and some heat.

Cleaned up and ready for a rebuild.

No lost parts this time - everything labelled and organized.

The choke rod (up and down to the right) partially removed - each carb
links to this plate which moves them all when the choke is pulled.

It only takes a bit of carb cleaner and a tooth brush to get the crud off. I blew it dry with the air line afterwards.
Caustic carb cleaner (it melted two pairs of latex gloves - for goodness sake, wear gloves!) isn't recommended on the insides
- I'll use a bit of gas and a clean toothbrush to make sure the innards are perfect when I get in there.

Some Kawasaki Concours ZG1000 carburetor links:

https://snapguide.com/guides/rebuild-kawasaki-concourse-carbs/
https://sites.google.com/site/shoodabenengineering/intake-and-exhaust
http://www.murphskits.com/product_info.php?products_id=130
http://www.randols.net/Connie/#_Toc276312906

Pulling the Carbs

The Concours' carburetor has become cursed by demons.  These carbs tend to not come back from sitting very well, though last year they didn't have this problem.  When I put them away they were running well, but no longer.

Yesterday I pulled the tank again and went over the vacuum tubes in detail - no breaks, no problems.  After putting it all back together again I took it out and had the same hesitation on throttle and back firing.  The bike feels seriously down on power too.

I was hoping to send the carbs down to Shoodaben Engineering in Florida for a spa session with Steve.  His prices are more than fair, but after having an economist (whatever the hell that is) as a Prime Minister for eight years, Canada's dollar is in the toilet and my $500US carb repair would cost north of $800 with shipping, customs and the exchange rate.  I paid $800Cdn for the bike in the first place.

So I'm rebuilding carbs!

In spite the many terrifying stories of carb removal on a Concours, I found the process pretty straight forward (thanks to Steve's video).  Warm up the rubber on the airbox to carb, they get nice and soft, and you wiggle the whole thing free.  With the carb on the bench, parts are ordered ($200Cdn for 4 kits - 1 for each carb) and I'm beginning to break it down to rebuild each.

There is always one more thing...

The open road awaits, and it's still waiting...

Recent frustrations with the twenty two year old Concours had me saying yesterday, "I like doing mechanical work, but sometimes I just want to go ride a fucking motorcycle."  It was a day in the mid teens Celsius (almost 60 Fahrenheit), and the sound of motorcycle engines could be heard on distant roads.  After spending the winter redoing the brakes, wheels and bearings, I got the Concours back on its feet only to find the carburetor has gone off.  The bike is running lean, not fueling nicely and back-fires when coming off throttle.  Instead of going out for a ride on one of the first nice days of the year, I was popping and swearing my way up and down the road by my house trying to get the carb to play nice.

Some vacuum diagrams on there, but not where they go.  Another
suggestion for lean burning/back firing conditions (which I have) are
the air cut valve (highlighted).

Some research into Concours carbs produced a baffling array of opinion and vitriol.  It appears that no one who works at a dealership has the experience or time to do carbs properly any more, and the carbs on the Concours are fantastically complicated.

I've done carbs before on cars, and labyrinthine vacuum tubes aren't a problem when you have a diagram to follow, but Clymers doesn't include one in their manual (unless it's for California bikes), and the Kawasaki diagrams show bits of vacuum diagram spread across the valve head blowup, the carb blow up, the fuel tank blowup, air box blow up and others.  Needless to say, trying to chase vacuum connections across half a dozen diagrams isn't easy.

Today I'm taking the fairing I just put on back off, removing the gas tank (again) and trying to make sense of the vacuum tubes.  If nothing obvious presents itself it'll be time to remove the carbs and go deeper.  I just did something similar on the XS1100 in the fall.  I haven't had time to work on it since because I'm spending all my garage time on the Concours.

I'm starting to think one project bike is enough.  The other one needs to be modern, dependable and there when I need it so I can, sometimes, you know, just go ride a damned bike.

Sources for Concours carburetor and vacuum information:

As usual, CoG is the place to go first:
http://forum.cog-online.org/index.php?topic=27077.0
http://forum.cog-online.org/index.php?topic=38095.0
http://forum.cog-online.org/index.php/topic,11914.0.html

CoG wisdom on Concours carbs:
Normally it is caused by dirty carbs and and not being sync'd properly. The dirty part can be from just a few days of sitting due to the ethanol evaporating....

it's very likely during the "cleaning" they did not dissassemble the air-cut valves from the 2 carb bodies prior to spraying with volatile carb cleaner. internal to each of those housings is a very delicate diphragm, not unlike the ones that lift the slides....during this process they damaged them, and at the least, never cleaned the rod attached to those diphragms that during decell, when the diphragm moves, opens a port to add fuel to the intake tract to preclude/prevent a "lean burn popping" upon decell. That is the sole purpose of those 2 valves, when they don't function, you get this result.

Check the vacumn stuff like you already mentioned. I had a back fire for a while, peeked under the tank, found the rubber cap on the #3 carb was split. Just for the fun of it, replaced all the hoses while there, good to go now.

You Cannot do away with the reed valves entirely unless you tap the ports in the actual valve cover and thread in some set screws. The easier way here is to leave the reed valves and metal covers on the valve cover, and remove all the vacuum hosing associated with the pair valve. Go to your local auto parts store, and pick up three 5/8" "heater core block off caps". They look like big vacuum caps, and also some 3/16" regular vacuum caps. Using the 5/8" Cap off the 2 ports left on the valve cover, and insert one backwards into the airbox hole. Use the 3/16" to block the intake ports.

http://www.zggtr.org/index.php?topic=15181.0
http://www.justanswer.com/motorcycle/21eu0-1897-kawasaki-concours-looking-fuel.html

Yamaha PW80

After doing a partial dismantling of my son's new (to us) '04 Yamaha PW80, I put it back together again and learned a valuable lesson in dirt bike ownership:  always turn off the fuel tap.  Other than carb pressure and gravity, there is nothing else stopping your garage from smelling like gas and a puddle forming.

The second dismantling came when it wouldn't start after the flood.  The spark plug was always dodgy, so I've gotten a pair of new ones (no problem finding them at Canadian Tire).

Good advice, straight from Yamaha

A tiny amount of Googling found me the Yamaha shop/operating manual, that covers everything from not carrying dogs on the bike with you to how to tear down the engine.

This is such a simple machine that it's a great way to get a handle on the basic motorbike system.  If you want to get handy with bike maintenance, start with a dirt bike (I started with a Concours...).

The next strip down has been more comprehensive, though to remove the tank, fairings and seat takes all of seven bolts.  The air filter was pretty bad with chunks of mud in the air box.  It's a shame that people treat a bike like that then just chuck in storage.  Why not clean it first?  In any case it's clean now.

The metal shop at school
sorted out the broken muffler.

I've got a busy hands afternoon after work checking the new plugs for spark (it's definitely getting gas) and putting it back together again knowing that I've taken it right down to the engine.  With how it took off last weekend (I impromtu wheelied down the driveway thinking it would barely be able to move me on it), I'm looking forward to seeing how spunky it is with a complete tune up.

With a new plug in it has strong spark - the carb is stinking of gas and it still won't start.  Time to pull the carburetor and sort it out before giving it another go.  Leaving it open overnight doesn't appear to have done it any favours.

The unhappy carburator

A Yamaha PW80 down to the mechanicals

I've got to get my mits on a me-sized dirt bike so we can go into the woods together up at the inlaw's cottage.  That DR600 Dakar is still for sale, I wonder if he'd take a grand for it.  It's a bit more than a mid-sized dirt bike, but it would do the business and also eventually adventure bike for me too.


It'd make a good Swiss army knife bike.