Moonbeam and Back: An In-Ontario Iron Butt & a Bike to Do It

The mighty Wolfe Bonham did a Moonbeam run this year as a part of one of his mega well-beyond an Iron Butt long distance rides.  I just popped it into Google maps and it happens to be a perfect first Iron Butt distance from home, and all in the province.

The starting Iron Butt is the Saddlesore 1000, 1000 miles in 24 hours.  They have a metric equivalent Saddlesore 1600 kilometre ride too.  The suggestion is to do a distance that can't be short cutted for credibility's sake.  Riding from Elora to Moonbeam and back is always going to be over 1600kms, no matter how you do it.  Another benefit is that by going up on Highway 11 through North Bay and back through Sudbury and on the 400, I won't be riding the same route twice.

The Tiger has become fragile, so I'm jonesing for a long distance weapon, not that the vibey and exposed Tiger was ideal for that, but it's what I had.  A few years ago Max and I rented a Kawasaki Concours14 for a ride in the Superstition Mountains near Phoenix, Arizona, and it was a glorious thing.  That Connie was a first gen C14, the newer ones have one of the highest load carrying capacities of a modern bike - so big that they could carry Max and I two-up again.  Another thing about getting back into Connie ownership (I used to own a C10), is that I'd have an excuse to frequent the Concours Owners Group again.

There is a low mileage (31k) 2010 current generation C14 for sale in Toronto with some cosmetic damage and a dodgy windshield.  I can sort out the niggles, and then this thing would eat miles like nothing I've had before.  There is a strange lack of Kawasaki Heavy Industries motorbikes on the Iron Butt finisher's list (Honda has six times more bikes, BMW over eight times more).  I want to represent!  I've owned more Kawis than any other brand to this point, so it'd also be coming home to team green.

This particular one is blue instead of tedious grey (Concourses tend to be very conservatively coloured), which appeals, I prefer a colourful bike.  The C14 has a number of optional touring pieces, including a variety of windshields, which is good because the slab on that Concours ain't comely.

Love the Milano from Guardians of the Galaxy.  The C14
would be getting similar higher visibility trim, especially
around those Testarosa strakes!

Fortnine has the National Cycle Vstream windshield for the C14, which would give me a smaller but more functional, better made and swoopier look.  The bike comes with a top box and panniers, so there isn't too much it'd need, other than sorting out the windshield and doing some touch up.  Seeing a blue bike, I immediately want to liven it up with some orange trim, Milano style.  Other than a full service and a few fixes, this bike is ready to do 100k.

The stock seat is already a comfortable thing, though I've enjoyed the Corbin on the Tiger so much I'd consider tapping them again for another custom saddle eventually.  The C14 Concours would be the biggest bike I've owned and could do something nothing in the garage can do right now, carry my son and I two-up while operating within the bike's weight capacity.  It would also be just what I need to make a run to Moonbeam and back in 24 hours as the summer winds up.

To Sell or Not to Sell

That'd get back what I've put into it and mean I've
put 15,000kms on it for free!

I put the Concours ZG1K project bike up for sale just to see how it would do.  I didn't expect a reply but got someone who is smitten with it and immediately offered me a trade worth about $2000 (a Phantom3 drone with a pile of expensive peripherals).  I took a drone training course last year and have been looking for a way to get some flight time in accordance with the Transport Canada flight planning we practiced in the course.  This would do that and also let me explore the aerial photography market first hand.  This is a trade that could end up paying for itself many times over.

Finding a trade that fits this well seems too good to be true.  In my experience, something that is too good to be true usually is.

I'm fighting that skepticism, but what I'm also fighting is some classism, morality and loyalty.  The young guy interested in the bike has the kind of online profile that makes you roll your eyes.  Every photo of him is half dressed and flipping the bird.  Which leads me to the moral quandary.  Handing this bike off to some yobbo who is likely to kill himself on it isn't something I can wash my hands of.  Then there is the loyalty.  I brought the Concours back from the dead.  We've done many long trips, including a once in a lifetime ride down the back straight of the Indianapolis Motor Speedway.  Had the carbs not shit the bed on the worst possible day (the first day of a new riding season after a long winter off), I would have still been happily riding it today.  Had they died the autumn before, I'd have had the winter to sort them out.  Bygones, but I love that my hands brought this old thing back to life.

So here I am, with a great opportunity to make some space in the garage while pursuing a trade that could end up being quite lucrative.  That space could be filled with a new project bike and I'd be back doing aerial photography again.  There is a lot to recommend moving on this, but I've got some issues to work through first.

The classism I can get past, but the selling a weapon to someone without the sense to handle it is nagging at me.  I'd feel responsible if something happened.  As heavy as that is, what really bugs me is feeling like I'm sending Connie on to an unworthy home where she'll be abused, broken and forgotten.  The mechanical sympathy that I apply to technical work often breaks out into full on mechanical empathy.  This is one of those times.  Maybe now isn't the right time to pass on the Concours.  Maybe what I should be doing is re-energizing this project and finishing it to the point where I can eventually pass it on to a more deserving home.  (Hmm, the classism crept back in again).

Installing LED lighting on the ZG1K Rat Bike

The mighty ZG1K modified Concours is just about done.  I've been plumbing the depths of the wiring loom working out how to integrate LED headlights and indicators into a 1994 electrical harness based on much less efficient bulbs.  Jumping into the future like that freaked out the existing flasher relay that manages how quickly they blink.  

If you're running big, old, inefficient bulbs, you get a nice steady indicator and hazard flash because those bulbs are heavy loads on the circuit.  The LEDs barely use anything at all by comparison, so suddenly the indicator relay is flashing so quickly it looks like a strobe light.

There are various ways to address this, but I think the easiest is to get an adjustable flasher relay (ten bucks on Amazon).  It plugs directly into the harness and can be adjusted for an indicator as quick or slow as you like.

I've still got to wire up the horn and headlights, but the bike is close to finished wiring wise.  I hope to be out later in the week checking off the other details and making sure everything is ready to go.  It has always been a quick bike, but now it's a ninety pound lighter quick bike.  I'm looking forward to seeing what it can do when it's finally road ready.

The ZG1K started out as a café racer conversion, but the muscular feel of the big-4 Kawasaki engine and the heavy duty frame made it look like more of a drag racer than a café racer.  Once I'd stripped it down I went with what I had.  If it had been a light weight single or twin engined machine then the café racer angle would have worked.  Had that been the case I would have gone with a finished, painted look, but once I started down the muscle bike route I started thinking it'd look better as a Mad Max themed post apocalypse rat bike.  Seeing Fury Road was how it got renamed the ZG1K Fury.

Mad Max: Fury Road isn't short on motorcycle inspiration.  The art direction in that film is amazing.

The paint on the bike wasn't too bad (it was rattle can but nicely finished and badged), but I ended up taking a sander to the tank one day and liked the result with the Kawasaki decal half sanded off; it felt much more radioactive that way.

With the old style round headlight but running LEDS and the stainless steel, drilled mounts I made for it, the bike looks old fashioned and rough but with weirdly futuristic details.  The rear lights look like they come out of Battlestar Galactica, but then the rest of the body panels (only where they are needed to cover up plumbing or electronics) are finished in some cut aluminum from the heat-shield that fell off my Mazda a couple of years ago.  Once committed to the rough look, I went looking for ways to stay consistent to it.  Ironically, the least ratty thing about the bike are the refinished and painted rims I had done before these whole thing started with a carb failure.  They never went on the original bike while it was on the road and they are by far the most perfect feature on this one that aims for imperfection.

Technical and aesthetic ideas for the custom bike were collected on a Pinterest board:



Once I've got everything together it'll be a review of all the main systems to make sure everything it tight and works well.  I'll bleed the brakes, make sure the engine is tight and dependable and then see how often I can get out on the thing.

Parts on Order Makes me Stop & Consider

Over the Easter long weekend I've rebuilt four carbs and put them back together again.  Unfortunately they won't go back on nicely thanks to two decade old rubber boots, so they're on order.  It's nice to have a forced day off.

If you're ever rebuilding carbs on a ZG1000, and the airbox on it is more than ten years old, it's a good idea to get some airbox ducts (that connect the airbox to the carbs).  Supple, soft rubber is important when connecting these up.  I tried for a frustrating couple of hours to get them to join properly.  This is especially difficult when the inner boots are rock hard, even when warmed up.  Steve suggests new carb boots to cut down on swearing, he ain't kidding:

Sixty bucks and should be here by
Wednesday.

I contacted my local dealer and they can have boots here by Wednesday.  They're charging less than they are going for on ebay or online retailers.  Score one for my local.  Sixty bucks means less swearing and an easy install.  Wayne, the Yoda-like parts guy at Two Wheel, says you're lucky to get two decades out of a set as they harden over time and eventually split.

With the weather going sideways again, there won't be much of a chance to ride any time soon.  Hopefully this means I can get this odyssey finished and the bike back on the road by the time the weather clears again.

The airbox ducts/boots that need replacing - the old ones are not only beaten up, but they've gone hard.
Even putting heat on them doesn't soften them up.  Note the flat spots up by the airbox that show you which
way to turn the boots.

Heating up the airbox boots - but they're too old!

A big empty where the airbox and carbs usually go

This ordeal has me rethinking things.  My wife suggested I unload everything except the old XS1100 and buy a regular motorbike that is more dependable.  When I started riding I got a dependable bike that just needed some cosmetic work.  It was so dependable it was tedious.  Since then I've gone back in time and enjoyed the world of carburetion and two decade old rubber, perhaps a bit more than I wanted to.

I genuinely enjoy mechanics, but never when there is a time demand on it.  I've already missed three riding opportunities because of the stuttering Concours, and this irks me.  The idea of wiping the slate clean and moving forward appeals.  I started riding late and moving through a number of bikes seems like a way to catch up on my lack of experience.  Maybe it is time to put sentiment down and move on.  I didn't start riding to watch the few lovely days we have in a too-short riding season pass me by.

A Tiger?  In my garage?

The little Yamaha and the KLX are gone now, netting me about $3000.  As it happens, a 2003 Triumph Tiger is available just over an hour away for about that much.  Come the end of the week I might be able to say, "a tiger?  In my garage?  Must have escaped from a zoo!"

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

Mechanical Sympathy

I've always had an over abundance of mechanical sympathy.  That sympathy often spills over into full on empathy for machines.  While I derive a great deal of joy from interacting with machines, the satisfaction I get out of fixing them is amplified by this natural inclination.

My first bike was a mechanically bullet proof 2007 Kawasaki Ninja 650r.  It had been dropped and scuffed, but it didn't need open heart surgery.  I was happy to clean it up and send it on its way, and while I got attached to it, it never felt like a two way relationship.

The Concours I have now is a whole new level of commitment.  Not only did I find it sitting in a field, buried in grass, but it took me a winter of rebuilding to get it on the road again.  In my first season riding it I've put on more miles than I ever did on the Ninja (it's a much more comfortable long distance tool).

Call me nostalgic (or perverse), but getting the four carburetors on the Concours running smoothly was very satisfying.  Even though I teach computer tech, I still find the clockwork nature of mechanical parts to have a grace that digital technology is lacking.  Listening to the Connie fire up at the touch of the starter on a cold morning and clear its throat is much more satisfying than listening to the clinical hum of a fuel injector making everything perfect.

I was out on the Concours again today - if the weather's dry I'm out on it.  I'm always astonished at how responsive such a heavy machine can feel.  It fits me well, needed me to save it, and then responded to that saving with thousands of miles of riding.  There may come a time when the Connie is more trouble than it's worth, but at the moment it's what I was looking for all along.

It's getting kind of crowded in there...

The Yamaha XS1100 sitting in the back of the garage will be my first go at a restoration, but as an owned bike it isn't really what I'm looking for.  It'll be my first go at a bike purchased for restoration rather than riding.  I'm curious to see how that process goes.




In the meantime, and completely off topic, here is some nice motorbike art I saw at Blue Mountain last weekend:

Revised Seat Geometry=Happiness

After installing a new seat cover (with some modifications), I took the Connie out for a ride.  The change in geometry is a compromise, but I think it's one I prefer.  In raising the seat height I'm causing more forward lean, but I'm also easing knee flex.

The gel cushion and extra padding on the new seat cover raises the seat a couple of inches.  I notice the forward lean a bit more, but the bike already has bar risers, so I'm not laying on the tank or anything.  The 6° knee angle relaxing is dynamite though.  I'd gladly take a bit more lean to ease the knee cramping.

The extra height above the windshield is negligible as I'm already looking over it by quite a bit.  With the extra height the bike feels like it fits me better.  A shorter rider would find a taller, wider seat difficult to manage, but I still have no trouble getting feet flat on the ground and riding is a much more comfortable proposition.

The seat itself is also much firmer.  Instead of squishy foam I'm sitting on thicker vinyl backed by higher density form over the gel pad.  The Corbin seat I was thinking about looks very low profile, so it would probably have bent my knees even more.  I think I've made a cheaper option actually work better for me.

A ride to the Forks of the Credit on a sunny, cool Sunday tested the new setup.

Your typical weekend in the parking lot at Higher Ground in Belfountain - everything from a
1947 sidecar outfit to Ducati Monsters to the latest Yamaha R1, and everything in between

Panniers make handy coffee holders
(I used them for a bakery pick-up in Erin)

Back home, the new seat's looking the business

The Seat of my Bike

After the ride to Indy I have a much stronger opinion about the Concours' stock seat.  It's soft and comfy on short rides, but on long rides it turns into a kind of torture device.  There are options for Concours seats that I can't justify on an $800 bike, but the cheaper option arrived, so yesterday during the rain I gave it a go.

It's tedious, but loosening the staples with a screwdriver makes
for clean removal with needle nose pliers.

The process took about an hour and a half to swap out the seat cover.  The seat fabric is held down by industrial staples.  I loosened them with a small flat-head screwdriver and then pulled them out with needle nose pliers.  It's time consuming because there are a couple of hundred of them holding the seat to the plastic base.

The cover peeled off relatively easy, only sticking where the Gorilla tape I'd used on the torn seam was touching the foam (that stuff is mega).

With the foam exposed I tried fitting the new seat skin and found that it had much more extra material on it.  I was looking to firm up the seat a bit any way, so I took the gel pad I got on the Indy trip and found it would fit under the new cover.  It would also raise the seat slightly, which would do my knees some favours.

Attaching a new seat cover is a tricky business.  The vast majority of swearing happened while doing this.  Rotating the seat so you can put weight on the staple as you squeeze the handle of the stapler helps seat it properly, but it's a pretty muscley process.  Getting the edges tight requires some practice.  This one came pretty close, but future ones I'll be pickier about and get even snugger.

In the meantime I've got a seat that feels firmer, sits a touch higher and isn't covered in tape.  I think the end result looks pretty good, and for thirty bucks plus shipping, it's a good cheap alternative to those sweet Corbin seats.

I found this seat cover maker on ebay.  The seat arrived quickly and is as advertised.  I can't speak for its toughness yet, but installing it I found that it was made of thick vinyl and the sewing was very strong.  It's a cool sunny day today, I'm going to give it a whirl and see how it does.

The stock seat tore on the stitching, Gorilla tape did the business until I could find a better solution.

Tragic Emptiness, New Possibilities

...and then there was one.

The Ninja was gone in six days, sold the first weekend I had it up for sale.  If you're looking to move your bike, prep it for spring and wait for the temperatures to promise spring, you'll have a quick sale.

I was asking $3900, but figured it would need some work done to safety, so I had a $500 cushion in there.  It went for $3200 as is, no extra cost on my part.  I'm happy with that, I bought it for $3500 safetied two years ago and put four thousand miles on it.

I've spent the last couple of days putting time into the Concours, getting it ready for launch...

I need to put some miles on this bike so I can begin believing that I can trust it.  I took it around the block today to warm up the final drive before changing out the fluid - that's the last fluid change on the bike, everything is new and synthetic now.

Around the block to warm up the final drive oil, and now it's changed with synthetic.  First time in that new jacket and
helmet too.  Both feel like quality compared to the bargain basement stuff I started with.

I'm still wandering around online looking at a very different second bike.  The KLX250 is on my short list now after seeing that one with a big bore kit.  We did our bike course on Yamaha 250s and I loved how light and flickable they were.  Having a small enduro would be the night and day difference I'd be looking for in having two bikes, not to mention it'd be very cheap to run.  If I had five grand laying about, I'd chuck it at a new one.

I suspect the Concours will need more TLC than the Ninja did, but if it turns out to be pretty bullet proof, a second bike with character could be this interesting '70s Yamaha.  I'd be able to get my scrambler vibe on with that!

Connie's Home

It's a very Kawasaki garage!

The Concours is home.  After a long bath (engine cleaner and a deep rinse) she fired right up.  I like this bike, even when it's covered in cobwebs and has been sitting outside for a year unridden it's still got fight in it.  The engine has gobs of torque and pulls hard.  The controls are stiff, but the gear changes are very smooth.  Shaft drive seems like magic.

So far she seems to be as advertised: good mechanicals but a mess aesthetically.  Over the next few days I'll be breaking her down and seeing what needs doing.  Hopefully there won't be any surprises.

It's a two bike garage now...

The Connie cleans up nicely