Kawasaki Concours C14 1400GTR Valve Check Part 3 - Putting it back together again

It's a slow process putting all this back together again. Even with a prolific number of photos and copious notes here on the blog I'm finding this a fiddly and frustrating process. My current plan is to get everything plugged in, top up the radiator and run it to make sure it's back together right before buttoning it up (there are a f(@# ton of  buttons).

The latest fun has been plugging the plethora of plugs over the valve cover back in.

I've got a couple of plugs (21) left after connecting everything else. The question now becomes: are oxygen sensor plugs not used on a 2010 Canadian market bike? 

Got the plugs in, except for those two top left of the rat's nest.

Here's a close-up. That white one has me baffled but perhaps it's the front cam sensor.

Tomorrow (assuming the late March ice storm we have in store doesn't throw us back to the stone age), I'll check for oxygen sensors on the exhaust, and if not there I'll know that one of those plugs is probably unused.

The ice storm was persistent but mainly pretty - no hydro lines down around here.

Other things to check are the front cam sensor (7-R on the diagram) which was very difficult to reinstall with a new o-ring. That plug is probably dangling down the front and needs to find a mate on top of the motor (looks like it's plumbed in under the front plastic guard). If that's my missing plug and the other one is an unused oxygen sensor then I'm about there.

After that gets settled I'll do one last look around for anything I might have missed before topping up the radiator and seeing if this thing'll run. If does I'll reroute the wires properly and should have it back to a point where I can start reinstalling all the fairings - which is a whole separate pain in the @$$, but at least one I've done before.

Then things get philosophical. Work has picked up and I don't have the patience or headspace to spend hours each weekend keeping these old bikes in motion. The temptation is to get $10k (CAD) between them and then buy something that can go when I need it to without so much TLC. 

I can save the wrench turning for when I retire. I enjoy working on them but trying to do a job this complex when I'm having to leave it for weeks on end while travelling makes a difficult job more so. Had I the time and space to do this daily when I wasn't juggling a demanding job, it'd have been an entirely different experience.

I'm loving the travel opportunities and my work is something I enjoy, but the deep bike maintenance doesn't fit with it at this point.

Haliburton was magical...

Flying out to the maritimes is never a bad thing...

...but those weeks away mean I'm coming back to an incredibly complicated job sometimes 20 days after I last touched it.

I've never made enough to be sentimental about vehicles and keep everything (I'd rather put those resources toward travel anyway). Time to simplify the bike stable to let me focus on riding when I can squeeze it in. I'll save the time suck that is older bike ownership for when I have more time to suck.

Haliburton School of Art & Design: Blacksmithing

 I've been wanting to refamiliarize myself with metal work for some time.  I don't like farming out work that I'm capable of doing myself and there was a point early in my working life when I was welding weekly as part of my millwright apprenticeship, but I haven't joined metal in over three decades. It's amazing how the time flies when quantum cyber research gets in the way.

Finding opportunities to develop these DIY technical skills in Canada where people don't like to DIY is a challenge. The only welding courses I could find were full-bore certificate courses for professionals, but then my wife found the Haliburton School of Art & Design. HSAD takes place in Haliburton, which you'll have heard about on TMD before because it's one of my favourite places to go for a ride in Ontario. It's also only about three hours from home.

HSAD offers piles of course options ranging from visual arts to technical crafts. If you're reading this you'll probably be interested in the blacksmithing course, not necessarily for the smithing but because it offers you access to expert metal workers in a fully tooled shop that will make you hands-on familiar with not only the hot forging of metal but also various other related technologies such as welding, grinding, polishing and plasma cutting. The three of us went up for the week with me doing the smithing, my son glass blowing and my wife water colour painting.

We were asked to bring a project, but what you really need to do for this is to start amassing ideas so when you're in the forge you've got a list to go after, that way you're not wasting time in front of a hot forge wondering what to do next. I showed up with my copy of the Rudge Book of the Road and an idea to build a metal sculpture of the line art in the front of the book.

My blacksmithing experience consists of an afternoon, so I thought this would take me the week, but by the end of day one I'd already worked out the rider in hot steel and started worrying that I'd run out of project.

I figured getting handy with welding would take a some time, but I forgot to take into account technological progression. Back in the day (in the late 1980s) when I was learning how to weld it was all stick (and no MIG carrot). It took about 15 minutes for Amie to talk me through the MIG process and ten minutes later I was tacking pieces together to get my layout right. No sparking a rod to see where you are either with modern instantly darkening welding helmets. Early efforts at joining pieces were messy but by Thursday I was knocking together pieces at will with clean welds. It's now just a  matter of practice to get back to a point where my joins are a point of pride.

Monday was a real hot-box with temps in the mid-thirties. In the forge it was well into the forties and I was drenched when I left. I should have shown up with better heat management methods and was very dehydrated when I left. I recovered as best I could overnight. The next morning I was still not feeling well but got myself in, got a handle on welding and put the rest of the design together.

I woke up Wednesday properly sick with the mother of all summer colds, but the only thing I needed to do to finish was the rider's scarf. With a bit more hot forming of steel and welding I had my 1920s art deco styled Rudge metalwork sculpture done.

On a side note - the propane forges aren't very big and don't work for long, complicated pieces, but the shop had dual coal forges with four working sides in the back room that let you heat longer pieces. The only trick with the coal forge is that it can get so hot it'll burn the steel (which looks like sparklers when it goes). The propane forges are set to not get that hot, but the coal forge can, so in addition to feeding the beast you also have to be careful it doesn't burn your steel. I ended up leaving the scarf in too long and it burned through at the back, but that wasn't necessarily a bad thing as I wasn't able to create the creases I was looking for in the ends. After burning it in half I was able to make the creases and weld the two sides back together, making it better than it would have been otherwise.

  

Old school, but it does offer some advantages along with some challenges...

I then got a primer on how the grinding room worked. The temperatures were dropping from Monday but when you're wearing face protection, a leather apron, long trousers, steel toe boots, leather gloves and a respirator, it's hot anyway. Even with all that and feeling right rotten I enjoyed getting a feel for grinding and cleaning up finished pieces. I get the sense that grinding is another one of those hands-on skills that can go surprisingly deep.

The end result was hung outside and I got given a spray on chemical that would prevent it from rusting while showing off the ground metal finish.

The finished piece looked so nice I got a clean image of it and then updated the logo on the site with it, and began the process of moving away from TMD logos focused on what I'm riding at the moment.

 

Amie Botelho was our instructor and she is all about hands-on learning. Most mornings we
did a 15-20 minute demo of tools and techniques that you could immediately find a use for. Any time you needed other equipment you'd do one on one safety and how-to training and be let at it. On the forge (and everywhere else in the shop)  Amie is incredibly efficient and that teaches you all sorts of lessons if you watch closely.

It isn't about how hard you hit, it's about how efficiently you get get hot steel out of the forge and under the hammer. It's also about turning your project over and looking at it closely as you work it. Smithing isn't about brute force, it's about attention and precision, but watching a master smith do it is infinitely better than reading about it in a book or hearing someone drone on about it in in a lecture.

Every demo was immediately followed by the suggestion to 'just do it', complete with lots of support in a class of 16 from Amie and shop-tech John. But the best part is that most of the 'students' are actually experienced smiths themselves. The ones around me had all done the four month certificate program at Fleming, so you're surrounded with experienced metal workers who are very free with support and advice (if you want it - you're left to your own devices if that's your jam).

If you're looking to hone your metalworking skills, or want to jumpstart them from scratch, this is a great place to start. Just make sure you show up with lots of ideas if you don't want to be cranking out spoons and bottle openers all week (unless that's your jam) - they're totally open to whatever you want to tackle. We had students working on everything from building a barrel forge of their own involving big industrial pieces, to yard art metal work using the small stuff.  Those experienced smiths in many cases were churning out all the smithing they needed for the year. One told me he'd make the $700 fee for attending for the week every day in what he was producing, making it well worth the cost.

Why come at it like this? Canada being Canada makes it very difficult for you to do things like forging or doing metal work on your own property without hanging you out to dry with insurance and infinite municipal, provincial and federal paperwork. Coming at it this way gives you access to a full service metal shop with all the tech and consumables, and with the safety and insurance challenges all taken care of. The bonus is you also get to hang with an interesting group of like-minded DIYers for the week, which is worth the price of admission alone.

The bandsaws looked like they were older than I am, and I'm feeling old this week!

Once I had the Rudge line art metalwork done I had a go at plasma cutting. I was originally thinking of making a variation on the Isle of Man TT trophy, but symmetrical wings are well out of my wheelhouse without more practice, so I turned it into an absurd door stop with a vaguely Honda theme.

 

Not bad for my first go with a plasma cutter!

Spoons are properly hard work. I found the edge of my forging techniques there quickly!

True that.

The forge at work.

He was early for lunch... this takes place in Haliburton, there are (lots of) deer.

Yep, I did a bottle opener too.

The propane forge at work.

Empty Algonquin Park

I managed a couple of days out on the bike around my birthday this year. Thanks to being freed from the shackles of the school year, I was able to do it outside of the May long weekend when the roads would be utterly mad with with ravening hordes driving the largest SUVs they could find and hauling every possible motorized toy to their second homes in the near north.

It ended up being just over 800kms over two days. 500kms on day one from home and up through and around Algonquin Park, then 320kms home on day two.  The Map.

The ride down Highway 9 to the 400 north was packed solid with transport trucks, to the point where I missed the turn north on Highway 27 because I was literally surrounded by the bloody things.

Finally on the 400 north (which was moving well on the Thursday morning before the long weekend), I let the Kawasaki fly and we shot up the road, finally clear of the convoy. I had three things going for me when I crested a hill right into the eyes of a waiting OPP cruiser.

#1: I was making time in the middle lane rather than the fast lane and was following another car

#2: The bike is awfully difficult to get a reading from thanks to not a lot of metal to bounce radar off of

#3: You can always count on some citiot blasting up the fast lane in a mega-sized German SUV

The cruiser lit the lights and pulled out only to collect said SUV out of the fast lane. He wasn't going much faster than I was but he can enjoy that ticket.

The 400 was (incredibly) fully functional and I was around Barrie in no time and moving up Highway 11 at pace. I pulled into Webbers because they have a nice new Starbucks where I got a coffee and stretched. In under two hours I'd covered the 172kms that got me clear of the gravity of the Greater Toronto Area and into the near north.

After a warm up (it was 5°C when I left just past 9am), I was back on the Kawasaki and heading north again. Gravenhurst was (incredibly) efficient and I slipped past what is often a backup without delay. By 11:30 I was grabbing a quick lunch and filling up in Huntsville and then it was Highway 60 into Algonquin Provincial Park.

I stopped at the West Gate to have a chat with the wardens and get my pass as I intended to stop at the Visitor Centre. After a nice chat with the young ladies at the desk I got my pass, set up the 360 camera and then got in motion ASAP because it's blackfly season and boy do they come out of the woodwork when you stop!

Into the park there was very little traffic. The only one I had to make space for was the massive German SUV thundering through one of the most beautiful places in the province at well over 120kms/hr (it's an 80 zone). If you play your cards like that, you're not likely to see anything!

Once clear of the traffic by the gate things got really quiet. An occasional car would pass the other way but there was nothing on the road in front of behind me as I went deeper into nature. It was midday so I wasn't likely to see any big animals (and I didn't), but birds were plentiful with birds of prey over the road and many others in the bush.

It was a glorious ride alone through the park - a place that comes as close to a church for me as anything can be. The bike was the perfect vehicle. I was moving fast enough to stay ahead of the blood sucking insects, but slowly enough to smell the lakes and woods and feel the thermoclines as a dipped into and out of valleys.

The visitor's centre is worth a stop if you're travelling through the park. The lookout off the back is a great view (and high enough up to be relatively bug free!). I would have stayed for a coffee and a snack but the restaurant was closed. It was a good opportunity to clean the bugs off my visor though.

By now it had hit the high of 12°C for the day and though it was sunny it was cool, especially when in motion on the bike. If I stopped I got sweaty and then the flies would come, so best to keep things moving. Out the east gate and then the plan was to ride south around the bottom of the park.

The Concours had been fantastic on the highways and had handled everything I asked of it. The only place I think the Tiger could have done a better job was on Peterson Road, which is your typical poorly maintained Ontario backroad with ruts and potholes that'll knock your teeth out. The sporty suspension on the Kawasaki didn't enjoy that bit of road. The Tiger's longer suspenders would have done the trick, but otherwise the Concours was the right bike for this ride, especially on the highways.

I finally pulled into Wilberforce about 444kms into the ride for a stretch and a drink (and to clean the bugs off the visor again). 

After a quick pit stop I was on my way again. The 118 is one of my favourite roads in the province and I twisted and turned my way down it towards Canarvon and Minden where I was spending the night. Only a long delay in Haliburton for road works slowed the ride down. At least I know the fans are working on the C14. They cycled three times while we sat there wondering what the f*** was going on. It turned out a water pipe had burst across the road holding things up.

I pulled into the Red Umbrella Inn just outside of Minden at about 5pm. After getting cleaned up I rode into town for some of the best Thai I've had at Suwan's Thai Cuisine and picked up a couple of local craft brews from Boshkung Brewing Social (Minden really has everything you need) before filling up and heading back to the inn for a quiet night by the lake.

The next morning I was up early and over to the Mill Pond for breakfast. Great eggs and bacon and then it was an empty ride down the 118 to Bracebridge, Port Carling and finally Bala for a coffee before the last stretch through Wahta Mohawk Territory before popping out at the 400 and getting into the rapid flow south.

I dodged and weaved around Creemore, stopping once to change into lighter gear because the temperature had shot up with the humidity and made it home before the thunderstorms started. A nice way to spend a couple of days on the road. I only wish I'd had more time.