Icy Days & Carburetors

It's been ice-storm icy here

Without warm weather beckoning (we've been in the middle of an ice-storm here) I'm in less of a panic about not having a bike to ride.  With an extended long weekend thanks to power failures and such, I've been hammering through four carb rebuilds.

The K&L kit I got came with a new bowl gasket, new pilot jet, washer and o-ring, and a new float jet.  Breaking down each carburetor one at a time (so I don't mix up parts), I cleaned out the carbs and blew them out with compressed air and then put them back together with the new parts.

Those little rubber bits
get crusty after 22 years
on a bike...

Adjustment wise I reset the float height (17mms with the float unweighted - held sideways).  I also reset the pilot jets to two turns out from snug.  The pilot jets varied from almost five turns out to under three turns out.  I'm curious to see how this affects fueling.  The manual suggested resetting them to what they were, and I did record them, but the factory setting is 2 turns from snug, so that's what I reset them to.  I'm not sure why I'd reset them to what they were when they weren't working well.

The carb rebuilds weren't particularly difficult, but they were a bit tedious (you're basically doing the same thing four times).  Things have ground to a halt again as I've found that I need o-rings to replace the old, broken ones that sealed the fuel lines between carbs.  With some new o-rings I should be good to put them all back together again and re-vacuum tube them with new tubing.

Rebuilding the first carb - it took a bit longer as it was more exploratory

The second videos hows the final two carbs and then discovering the need for o-rings -both videos are based on photos taken every 10 seconds compressed into a video running at one photo every 1/10th of second.

As an aside, I thought it would be a good idea to go through Motorcyclesuperstore.ca, but they seem to have pulled back from offering Canadian customers a clear view of their prices.  You used to be able to buy in Canadian dollars and there were no surprises.  When you buy now they charge in U$D, so you've got to do some math to figure out how they compare to Canadian retailers.  It looked like they came out about twenty bucks ahead of an equivalent Canadian order, until I got the COD message with border taxes.  Suddenly that twenty bucks turned into paying an extra ten.  I liked motorcyclesuperstore.com, their customer service went above and beyond, but their lack of clarity around pricing of orders to Canada puts them in the same category as any other US distributor.  I'm not happy with canadasmotorcycle.ca's 'easy' returns (they charge you for shipping), but I'm not playing roulette with customs costs again.  I'm afraid that's the last time I'll use motorcyclesuperstore.  I need to start looking into other Canadian based motorcycle retailers.

Two down, two to go...

The pilot jet (centre) - has a spring, washer and o-ring underneath.

The float bowl off and being cleaned out - the floats are held in a pin at the bottom - the float jet hooks on a tab in the middle

Carb Photos:
https://goo.gl/photos/kPhLXuQnb8HmdQFs9

Bye Bye KLX

Selling a bike is always difficult.  In the case of the KLX it happened very quickly.  It didn't cost me anything to own it (what I got for it covers what I paid for it including the safety).

Unlike the Ninja before it, the KLX didn't get much seat time with me so I don't have a strong emotional bond with it.  I also didn't modify it at all, though I was tempted to.

In a funk the other week because I couldn't go for a ride on one of the first ride-able days of the year, my wife suggested I get rid of some bikes and get something dependable.  If I have to pivot around a bike, it would be the Concours (I'm emotionally invested).  It's a bit much to ask a 22 year old bike to be a daily rider, but that's what I was doing.  The goal now is to have two bikes:  the Concours and something newer and more dependable that can do commuting duties when needed but also offers me a different kind of ride than the big two-up friendly Concours.

I'm still fixated on a Versys.  There are a number ranging from just over $3000 for '07s to up in the 5ks for a 3-4 year old model.  If it is the all purpose/dependable machine I'm looking for, then a KLE will soon replace the KLX.  Having said that, this is an opportunity to consider a wide range of general purpose machinery, and I should take it.

Now to get the XS1100 running so I can sell it and look to create a more ride-able stable of bikes.  Looking at the brakes yesterday, I suspect the XS is need of some pretty serious fettling before it'll roll anywhere.

The calipers are unseized and rebuilt.  Now I'm looking for the source of the leak in the master cylinder.  With the front brakes sorted I'm going to try and fire up this dinosaur.  A running bike sells for way more than a door stop, and I want to hear it running before I let it go.

If next fall I'm putting the Concours and a more modern dependable bike to sleep and wheeling a winter project bike into the garage, I'll be in my happy place.  A winter project like this!

Scrambling Versys Thoughts

Some home-made Versys diagrams of what a high/scrambler
type exhaust might look like - it looks good!  I have to wonder
why Kawasaki never did this with the bike...

A more all round capable Versys...

The asymmetrical nature of the rear shock (only visible from the right side of the bike) means that, aesthetically, a high pipe might look balanced running up the left/empty side.

The pipes and muffler are all usually mounted at the bottom - not ideal for off roading where soft exhaust components can get pounded flat.  Having them wrap around the left hand side of the bike and finish up under the rear frame means a protected exhaust.  I've always wanted to try custom exhaust building, this might be my chance.

Pipes and muffler out of the way mean more ground clearance even with a steel skid plate installed.

At five kilos lighter and with a four horsepower bump, the Akropovic tail pipe for the ER6 motor (what the Versys has a version of) would lower weight while offering a gain in power.  The titanium tail pipe would also look good while not taking up too much space under the rear fender.

Creating a custom metal heat shield around the pipe would protect from burns while also protecting the pipe.  Most scrambler style/high exhaust pipe use this as an excuse to decorate.  The ER6 parallel twin is a very efficient and cool running engine.  Even the exhausts don't get nuclear hot.  With some careful routing and smart use of heat shields, this should be doable.

The new exhaust might upend the fueling, so this would be an ideal opportunity to try out a Power Commander and get into computerized fueling control for the first time.

The next step would be to find some scramblery tires.  A road focused tire with some off road capability would do the trick.  Fortunately, Pirelli's MT-60 dual sport tire not only gives the Versys some real off road capability, but it also improves road handling over the stock tires.  They come in Versys stock sizes (120/70-R17 fronts and 160/60-R17 rears) and cost about five hundred bucks for the pair online.

At under four hundred pounds the Versys is already a light machine.  The goal would be to make changes that don't add significantly to the weight.  This light weight, multi-purpose Versys makes for an interesting Swiss-Army knife of a bike.

You'd be hard pressed to find a
more neutral riding position.

A 1 inch seat rise only makes it
more relaxed and usable.

A taller rider online said that increasing his seat height made the bike an ideal long distance tool.  A number of places seem to offer that very modification.

The stock windshield is a bit weedy as well.  I got a Givi windshield for the Concours and think it a great piece of kit.  The Givi item for the Versys is slightly taller than stock (not a problem, I'll look over it anyway), but looks good.

The only other thing I would add is a top box, allowing for carrying smaller items while keeping the bike as narrow as possible.  I installed a Givi topbox on the Ninja and it worked well without being too bulky.  It also allowed my pillion a place to rest against.

I've found well used ('07, 80+k kms) Versys for $2800, and much less used ('09, <10k) Versys for $4500 online.  If I can unload the KLX for $2500, my son's little Yamaha for $600 and the XS1100 for $1000, that'll give me about $4000 to put into a relatively new, dependable, fuel injected bike that I can then begin modifying!

The mods listed here are as follows:
Custom pipe         =  tbd - most of this would be diy
Akropovic exhaust   = ~$500
Power Commander     = ~$400
Pirelli MT-60 tires = ~$500
Custom seat rebuild = ~$700
Givi windshield     = ~$180
Givi topbox & hw    = ~$400
                      -----
                      $2680 + diy exhaust piping            
Twisted Throttle's Versys ADV makes me want to add to this.

More Versatile Versys Links

http://www.motorcycle-usa.com/2011/12/article/2011-kawasaki-versys-project-part-2/

https://www.canadasmotorcycle.ca/pirelli-mt-60-rs-sport-corsa-rear-tire.html?gclid=Cj0KEQjwzq63BRCrtIuGjImRoIIBEiQAGLHdYWSmxI0JjOz5nLndRdEQqiUyqy2EV8vH2LIWmAgwsXkaAu8f8P8HAQ

http://www.motorbikesaddles.com/Kawasaki%20Versys%20Tall%20Seats.htm

http://www.kawasakiversys.com/forums/

http://www.pirelli.com/tyres/en-ww/motorcycle/all-tyres/sheet/mt-60-rs

http://www.giviluggage.co/givi-product-focus/bike-overview-kawasaki-er6-nf-05-08/

http://www.giviusa.com/my-motorcycle/kawasaki/versys-650-06-09/447fz-monorack-sidearms-detail

http://www.giviusa.com/givi-products/cases/monolock-cases/e340nta-34ltr-matte-black-case-detail

http://www.kijiji.ca/v-sport-touring/kitchener-waterloo/kawasaki-versys/1146380401?enableSearchNavigationFlag=true

http://www.twistedthrottle.ca/shop-by-bike/kawasaki/versys-650-07-09

http://www.twistedthrottle.ca/news-and-events/adventure-motorcycle-magazines-twisted-throttle-and-sw-motech-equipped-kawasaki-versys.html

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

Dream Racer

Triumph included a link to this on their email newsletter, so I gave it a whirl on Vimeo.  At nearly $9 it's an expensive (48 hour) video rental compounded by some stuttering even with fibre at home internet.  Looking at the code it looks like Vimeo segments the video to prevent copying.  Those segments kept stalling on transition, which is pretty frustrating, especially when you just paid a premium price to see it.

I like Charley, but he
wasn't the guy to see
this through

Technicalities aside, the film itself is very engaging.  It isn't just about a run at Dakar (like Charlie's was).  The man making the film, Simon Lee, is in his thirties and feels like his dreams of making a film are ebbing away under the pressures of middle aged life.  The man trying to go to the Dakar, Christophe, is a former North African motor-cross champion who failed to complete the Dakar the year before.  He is a skilled rider, but spends all his time in a suit and tie doing business and trying to drum up the money to get himself to the race.  The expectations of middle-aged life are barriers in both men's struggles.

When desire conquerors
circumstance you get a
better story

You'd expect a fully financed, technically supported, off-road experienced forty year old rider coupled with a Dakar veteran mentor and a spare rider to hand you his bike when your's breaks to finish the race (he didn't).  You'd not expect a single thirty-something experienced racer who has to turn his own wrenches and barely managed to find a bike and get enough money to attend the race to finish (he does).  What matters more, financial support or the will to succeed?  This film sheds light on that question.

Along the way you get to see the Dakar without the money lenses of sponsorship.  This purer Dakar hearkens back to the beginnings of the race (a good documentary to watch about this is BBC's Madness in the Desert).  But you don't have to suffer through poor footage from amateurs to see this raw Dakar.  What you get is video shot by a guy who knows how to shoot video and edited by an expert.  The whole thing is then wrapped in an original soundtrack that supports and nurtures the narrative.  If you're used to watching half-assed video of motorcycle based adventure, this isn't that.

A teary conclusion is well earned, and stirs up deeper
philosophical questions around media dilettantes & the
committed racer...  

When you get to the end and everyone is in tears you'd have to be a robot not to share that feeling with them, and it's not all just about Christophe's race either, it's also about Simon's journey as a documentary film maker.  Both men defy expectations and pursue a dream at great personal expense (emotional, physical and financial).  It's the kind of story most of us who live in a world that doesn't give a damn about what we dream of doing can relate to.

If you enjoy a quality, motorcycle themed film, this will do it for you.  It's well shot and brilliantly edited and musically scored.  The filming is such that you get to know Simon and Christophe who are both painfully honest in front of the camera.  The narrative (aided by that brilliant editing) takes you from introductions, to desperate attempts to source the money and prepare for the race and then tosses you into the Dakar without the antiseptic third person corporate perspective you usually see it from.  By this point you're emotionally invested in both men's journey.

I recommend this film.  I only wish I could have ordered the DVD for a few dollars more and been able to watch it without the interruptions and technical headaches.

When a film leverages the Dakar to raise questions around commitment to challenge through skill and determination,
and does it well, you've got a winner.

Christophe riding injured.  As long as he is conscious, he isn't going to stop - remarkably sympathetic to his machine as well.

A naked Dakar bike, personally paid for, no corporate spin; not what the modern Dakar is about.  It would be nice
to see the money around the Dakar put a bit aside to ease the entry of privateers into the race - they make for better
stories than the stone faced, well paid professionals.