Are you ready for your fitting? Tailored Motorbikes & Micro-manufacturing...

I just read a good article in Motorcycle Mojo called, "Building The Perfect Bike."  In the article the author supposed that since no 'off the rack' bike fits properly, he would give himself a new bike budget, buy a lightly used machine and create a custom-fit.  His exercise made for an interesting process, and he got closer to a custom fit, but it's still far from a tailored motorbike.

Cycle-Ergo lets you quickly
assess a bike's fit, and allows
for modifications to control
locations.

I've used Cycle Ergo to great effect when considering off-the-rack bikes for fit, but you have to wonder how long it will be before we migrate from mass-produced, generic machines to personalized/tailored ones.  In that future Cycle Ergo two point oh will 3d scan you and get your performance needs and produce a custom machine specifically for you.

My day job is as head of technology at our local high school.  My focus there is in information technology and electronics.  I work closely with our technology design teacher who has a background in robotics.  We've both watched the rise of specialized manufacturing with great interest.  Our labs have taken on 3d printers, digital routers and five axis digital CnC machines in response to this evolution in manufacturing.  The prices on these devices have dropped dramatically over the past few years.  It won't be far off when you'll be able to custom build parts from scratch for a fraction of what it used to cost.

Computer controlled, small scale manufacturing will radically change our understanding of what have always been industrial scale production processes.  I suspect that in the future most of the manufacturing process will decentralize from factories and into regional shops that can produce customization on a scale unimaginable to 20th Century industrialists.

Some of the very high end motorcycle manufacturers are already embracing the idea of tailoring a machine to the rider.  Even a tiny volume manufacturer like Brough Superior can now consider machining all its own pieces in response to individual customer demand.  As the costs of personalized machining come down, the idea of a tailored motorbike will become the standard rather than the exception.

When you can cut your own pieces,
you can build your imagination.

One of the unseen hands that is encouraging the latest surge in the customized motorcycle scene is access to machining and manufacturing processes that used to only make sense in thousand plus unit runs.  You can build an astonishingly well built customized machine nowadays because you can build the bits you need for it to your own specifications.  Custom builders are a step toward truly individualized production.

Rather than plugging my dimensions into a database of bikes, one day soon I'll be plugging my dimensions and performance needs into a blank template and watching the perfect bike form around me.  The seat would be designed for my backside, the handlebar grips built to fit my hands.  The system would then CAD/CAM out all the parts and custom produce everything from the frame to engine components, all to my specific needs.  The distinction between OEM and aftermarket will disappear, there will only be builders.

Now *that* would be a perfectly tailored bike!

A Day In The Shop

I took a day off from the enormous deck I've been building to work on the Concours.  After the initial clean up I got the instrument cluster off in preparation for a new speedo cable.  This looks like a pretty easy job.  The cluster is only held on with two bolts and the speedo cable runs directly from it to the front tire.  You slot the ends of the cable in and do them up and you're off to the races.  Replacement cables only run you about ten bucks.

'94 Concours clutch lever assembly.  Those
little bolts that hold on the cover are 4mm
and hard to source (not much in the way of
metric bolts around here).  The clutch lever
meets up with a pin and various odds and
ends that connect it to the reservoir.

I've also removed the rather sad looking handlebar end weights and looked at the clutch lever.  The former owner said it was missing a grommet, but it looks like other odds and ends are missing as well from the lever assembly, which is remarkably fine boned.  I've looked up prices online, but there don't seem to be any Canadian online parts sellers that work in this kind of OEM detail.

Considering the relatively low cost of the odds and ends I need (about $30), it seems silly to buy American and deal with customs hassles and shipping costs that almost equal the cost of the parts.  Even with dealer markup, my local Kawi dealer should be able to beat the shipping markup.

I finally got to the various fairing bits and panniers and they look to be in good shape after I got the cobwebs, mud and grime off them.

The current plan is to get the speedo operational, check other details and then put her back together again and take her in for a safety check.  If all goes well there I'll begin the process of putting her back on the road.  With any luck I'll get some miles on before the snow falls and then spend the winter stripping her down for a paint job.

The instrument cluster is a simple removal, two bolts
underneath hold the unit to a subframe.  The whole
thing is connected to the speedo cable out the bottom
and a couple of wiring harnesses out the side.

Many bits and pieces make up a
Kawasaki Concours.  The instrument
bezel (middle) cleaned up nicely after
a soak in some armourall.

I finally got the Connie up on the centre stand.  If there is a trick to that I'd love to hear it.  I ended up putting a wooden
ramp out back and man-handling it up it in order to get the stand down.

Concours Owners Group

I've been told that one of the best parts of owning a Concours is the Concours Owners Group.  I just signed up for a year's membership and I'm already overwhelmed by all the information in the forum.

Looking at the calendar, there is a local meeting tomorrow only a 45 minute ride away.  For a group that covers a huge geographical area, they offer a chance to meet face to face  around the corner; very cool.

Between COG and the huge aftermarket available, it looks like the Concours is the canvas I've been looking for.

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

 

Connie

cob-webs and rust...

  The Kawasaki Concours was a rough looking old thing, but very mechanically sound.  It only has 56k on it and was tight, dry and sounded strong.  The owner was a long time rider who is being sidelined by arthritis, he knows how to look after a bike.  Mechanically this Connie is well cared for, it's just a cosmetic mess.  I'm good at cosmetic messes.  I offered him $800 and he says OK.  Hopefully I'll have it home next time I post.

I'm going to be spending some time stripping this old girl down and cleaning her up.

In the meantime I think I'm going to take a friend's advice, get both bikes!  My current plan is to transition to the Connie from the Ninja at the end of this season, sell the Ninja and go looking for that Interceptor of my dreams.  Since the Ninja was a much newer bike, I think I'll be able to diversify my two wheel portfolio without putting any more money into it.

Dreams and Realities

It's the bike on my bedroom wall when I was a kid.

As near as I can tell the '84 Interceptor is still for sale, though the owner isn't responsive to emails.  I'll end up phoning and see if I can get up there next week to look at it.

In the meantime, a Concours appeared nearby that looks like a good buy.  Mechanically good but a bit rough looking, it's priced to sell.

So here I am again at the intersection of fantasy and reality, wondering which way to turn.  The Interceptor isn't running, will need a complete rebuild (it's been sitting for a decade), and costs $700.  It's also a good couple of hours away and would need me to find/rent a vehicle to bring it home.  The Concours is twenty minutes away, roadworthy and is $1000 or best offer.  Price wise there is little between them.

Owning a bike at all is a dream come true, so the dream versus reality distinction is finer here.  The question now is which direction do I want to go next?  Last year I did a lot of miles on the Ninja.  This year I've been riding a lot of different bikes and the Ninja hasn't seen me as much.  I want to continue to expand my riding repertoire.  Both bikes offer bigger engines and variations on the sport touring theme.  The Interceptor would be my first Honda, the Kawi would introduce me to shaft drive.

The purpose of buying a fixer-upper is to have something to spanner in the winter months, so the idea of repairing the Honda isn't fearsome, it's something I'd look forward to, and parts seem to be available for it.  There are also a lot of information sites on the web about it.  I'd always assumed I'd buy a Honda bike, but I've been waylayed by Kawasaki's awesomeness.  I'm trying not to be brand specific but rather honour the engineering.  Having said that, I've always had a crush on Hondas and Triumphs.

She doesn't look like much, but she's got it where
it counts... If it worked for Han Solo, it'll work for me.
Is this my diamond in the rough?

That Concours needs some TLC too though.  The Concours is ten years newer with lower kilometres.  This seems like a no-brainer, but this is where emotion clouds the decision.  The Interceptor has been my dream machine forever, I've always wanted to own one.  The Concours is a much more usable machine.  My son and I could tour on it comfortably and do a lot of miles.

The Concours is also a gentler machine, and while I'm still an adolescent when it comes to riding a motorcycle, I'm 45 years old otherwise.  That the Concours is a big guy who can move with surprising speed is a much better fit for this balding, middle age guy than an '80s superbike.  There comes a time when you don't want to look absurd on a bike, or maybe that just doesn't matter.

In a more perfect world I'd have a big enough garage to get both.  The Interceptor would get stripped down and prepped as a vintage race bike.  I could then live out my dreams of riding it on the safety of a track.  The Concours would get fixed up and cover some huge miles, occasionally finding some twisties to show off its athletic prowess.

Buying a bike has been such a visceral experience that I think I'll have to see both in the flesh before I make a decision.  I'm hoping that the Kawi strikes an emotional nerve with me because if she can get under my skin I know she'd be a better fit than a feverish teenager's dream.

Track Day Planning

I'm pretty keen to go do a track day, and I have a buddy who is the same.  The Grand Bend Motorplex does motorcycle open lapping on its track.   I found GBM through motorcycletrackdays.ca.  The upcoming SOAR racing event at Grand Bend offers open motorcycle lapping prior to their weekend events.  That might be a good time for two nØØbs to go as there will be experienced track day people on hand to help us fumble through the technical inspection.

I figured it would be a show up on what you rode here on and go on the track, as you would with a car, but bikes seem a bit more involved.  Here is the list of motorcycle specific technical requirements:

• Is your kickstand secured? Your spring return isn’t enough on a racetrack. Use a plastic strap tie or duct tape to secure your kickstand in the up and locked position before you come to tech. 
• Tape over your speedometer. It’s the rule.
• Make sure your throttle returns quickly and positively. We want to see it snap back when you release the grip. 
• Change your antifreeze for straight water. If your bike puts antifreeze on the surface, it shuts the entire track down and may result in suspension. Antifreeze is 100 times worse than water on asphalt (It’s like wet ice). Swap it out for water before you proceed to tech. 
• Tape over or remove lights, signal and mirrors. They all shatter and they all puncture tires. 
• Brakes: Make sure they’re properly functioning, front and back, with no leaks, because we’ll check. 
• Chain: Check your drivechain adjustment. Too tight or too loose means breakage. Refer to manufacturer’s specification. Also, check your master link. A rivet style link is preferred, but a standard ‘slip on’ while suffice if you put a dab of silicone on the key to secure it. 
• Now that you’ve ensured your brake lines don’t leak, check the rest of the bike. Your engine and suspension components must also be leak free. 
• Overall track worthiness: These are the small things that can lead to disaster. Loose lines can snag. If it can flop around, it can be snagged and lead to a crash. 
• Body: All body parts must be secured or removed. 
• Mechanical: Check your fasteners and ensure they’re secured at recommended torque. 
• Tires: Properly inflated, with structural integrity intact (sidewall, tread, steel-belts, bulges).

Most of that is common sense/maintenance, but there are a couple of bits that will require some thought.  Tying up the kickstand is all well and good, but that means you're bringing a rear stand to keep the bike upright.  Swapping out the antifreeze also means you need to bring some distilled water.  Some tools, disposable gloves and fluids would probably be a good idea too.  Suddenly the back of the bike I want to ride to the track day is looking like a hardware store.  You wouldn't want to ride an hour and a half to a track to find out you don't have what you need to go around it.  Short of asking for a pit crew to accompany you in a four wheeler, riding solo to a track day seems difficult if not impossible.

Of course, this leads you down the road to a trailer, which then begs the question, why use your road bike for track days when you can pick up an older sport bike for not much, not have to pay for road insurance on it and spec it out specifically for track days.  Stripped of lights and needless accessories like rear foot pegs and indicators, you'd be ready to ride as soon as you roll it off the trailer, and the machine would be tailored for the track.

I've been to several racing schools, but the one time I really got into it was while living in Akita, Japan.  Kyowa Race track was a small carting track deep in the mountains south east of the city.  Kazutoyo, a student of mine, was an avid racer (he came to Canada for a summer to participate in a Mosport racing mechanics program).  We'd go up there half a dozen times in the summer and spend the day hauling the carts around that bendy circuit as quickly as we could.

The vehicle of choice for the carts and the paraphernalia that went with them was a cargo van.  We'd be able to fit three people, the tools, the disassembled cart and spare tires and other odds and ends all in the van and head to the track.  Riding around at break neck speeds was awesome, but I have fond memories of all the fettling that when on in the pits too; it's all part of the race experience.

Ford Canada's handy Transit Van Builder got me all
set with a customized utility van that could carry two
bikes and gear with ease... things I'd do if I were rich!

Now that I'm thinking about doing a track day on two wheels I'm tempted to imitate those Japanese carting guys and get what I need to make a track day possible.  I've been wishing for a trailer several times this summer to haul lumber.  Having one on hand and a vehicle to haul it would be handy for more than just track days.  

Or just win the lottery and get the full on racing support van.

If Mechanical Sympathy were to go full on into racing, I'd grab that 1000cc VFR from Angus (in my Transit race van) and prep it for racing.  Stripping off all the lights and extras and minimizing it down to a race bike.  I'd be a dangerous man if I had more money.

In the meantime I'm still trying to look for ways to ride my Ninja to the track and do some laps without dragging along someone in a cage to support the activity.

Links:

Motorcycle track day primer: a good explanation of track days.
Beginner's Guide to Track Days in Ontario: a great checklist on how to approach track days - renting a bike is what I'm now looking into...