Kawasaki ZGRX 1200 Concours - BARF

bergmen · 12-09-2020, 01:01 PM

Some of you may know about this project I started in April of 2007 and began first test rides in November of that year.

Briefly, I took the engine from a 2003 Kawasaki ZRX1200R, converted it to shaft drive, designed my own front engine mount and ended up with a 1200cc Concours (more than 25% more horsepower and torque).

There is a LOT more to this story that I can expand on if anyone is interested. BTW, once I had all the bugs worked out I rode this for seven years with zero issues until I got my 2014 Yamaha FJR1300A.

Dan

Frame Maker · 12-09-2020, 04:44 PM

Quote:

Originally Posted by bergmen

...Briefly, I took the engine from a 2003 Kawasaki ZRX1200R, converted it to shaft drive, designed my own front engine mount and ended up with a 1200cc Concours (more than 25% more horsepower and torque).

There is a LOT more to this story that I can expand on if anyone is interested...

You're now in the right place, so go ahead and post up your story. And be sure to include lots of pictures, we like pictures

**budman** · 12-09-2020, 06:52 PM

The conversion to a shaft drive alone is worth hearing more....

Maddevill · 12-09-2020, 07:46 PM

I agree.
Mad

bergmen · 12-09-2020, 07:51 PM

Quote:

Originally Posted by budman

The conversion to a shaft drive alone is worth hearing more....

Well,the original ZG1000 engine block is identical to the ZRX1200 block from the input shaft rearward. Same bearings in the transmission, same center-to-center spacing, same oil system, everything. Same rear engine mounts.

I needed to install a six-speed Concours transmission in order to have the bevel gear coupling on the end of the output shaft. The bolt pattern for the bevel gear was there in the crankcase output side with one exception. I needed to drill and tap one extra hole (the boss was there). The ZRX clutch basket (necessary for the ZRX primary drive) bolted right up to the Concours input shaft.

Here are pictures:

bergmen · 12-09-2020, 08:08 PM

Before I worked on the transmission change over I needed to design a new front engine mount. The ZG1000 engine was a stressed member of the frame and the cylinder head was mounted to the frame as a result (same as the Ninja 900 which this motorcycle was derived). The ZRX engine was not mounted this way. I designed a new engine mount using my 3d CAD system.

bergmen · 12-09-2020, 08:12 PM

I was able to acquire a spare Concours frame to use for developmental purposes so I could leave my Concours unmolested during the engineering of this conversion.

**budman** · 12-09-2020, 08:14 PM

Sweet.

Drilling the hole had to be the deal. Screw that up and start over.... with new cases. I am impressed.

bergmen · 12-09-2020, 08:16 PM

The Concours shift drum, shift shafts and gear indexer arms mounted in the crankcase without modification. Here I am doing a complete function test of all of the transmission components in the ZRX case.

bergmen · 12-09-2020, 08:25 PM

Quote:

Originally Posted by budman

Sweet.

Drilling the hole had to be the deal. Screw that up and start over.... with new cases. I am impressed.

I mounted the bevel gear case to determine exact location of the hole to be drilled. I marked it with a drill of the same diameter as the clearance hole in the case. I then measured the depth of the other holes in the case and used an extension drill concentrically located in the case clearance hole to drill the pilot hole.

bergmen · 12-09-2020, 08:25 PM

More tomorrow, I'm heading to bed...

Pushrod · 12-10-2020, 02:04 AM

Drilled into a case, got it square and straight, with a hand-held drill?

That qualifies for admiration.

kpke · 12-10-2020, 05:37 AM

EGADS. Subscribed. That is a really cool transformation.

I love the photo with the frame/engine supported by the galvanized pipe.

And all the other photos

Quote:

Originally Posted by bergmen

I was able to acquire a spare Concours frame to use for developmental purposes so I could leave my Concours unmolested during the engineering of this conversion.

**auntiebling** · 12-10-2020, 06:58 AM

This is awesome

bergmen · 12-10-2020, 07:18 AM

Quote:

Originally Posted by Pushrod

Drilled into a case, got it square and straight, with a hand-held drill?

That qualifies for admiration.

It was fairly straightforward to maintain concentricity by using the clearance hole in the bevel gear case as a guide. I took my time and was very careful. I then tapped the hole (M6) with a taper tap followed by a bottoming tap I had to make myself (ground the end of a spare taper tap). Hard to find M6 bottoming taps in this town.

Dan

12-09-2020, 01:01 PM	#1
bergmen Veteran Join Date: Feb 2006 Location: Ukiah, California Motorcycles: 2014 Yamaha FJR1300A Name: Dan	Kawasaki ZGRX 1200 Concours Some of you may know about this project I started in April of 2007 and began first test rides in November of that year. Briefly, I took the engine from a 2003 Kawasaki ZRX1200R, converted it to shaft drive, designed my own front engine mount and ended up with a 1200cc Concours (more than 25% more horsepower and torque). There is a LOT more to this story that I can expand on if anyone is interested. BTW, once I had all the bugs worked out I rode this for seven years with zero issues until I got my 2014 Yamaha FJR1300A. Dan Attached Thumbnails

12-09-2020, 06:52 PM	#3
budman General Menace AMA Life Member #203453 Highway Aviator Founding Member Top Percent Poster Community Contributor + BB Moto Junkie Join Date: Apr 2002 Location: Palo Alto, Ca. Motorcycles: Keep me rocking life Name: Budman	The conversion to a shaft drive alone is worth hearing more.... __________________ Your friendly neighborhood.... Budman BARF Terms of Service Be a BARF Contributor! Support those that support Barf! BARF Sponsors 1Rider introduction on KFOG Bone heads and bikers podcasts Racism and RIP threads on Barf - FYI Barf is more than a dub dub dub dealio Godspeed Mom Pit Ho Godspeed Nicky #69 Hoho AMA #203453

12-09-2020, 07:46 PM	#4
Maddevill KNGKAW AMA #: 542337 Join Date: Jun 2005 Location: Hayward Motorcycles: ZX14,GS750E, KTM 450/540 Name: Steve	I agree. Mad __________________ If your nose runs and your feet smell, you're built upside down.

12-09-2020, 08:08 PM	#6
bergmen Veteran Join Date: Feb 2006 Location: Ukiah, California Motorcycles: 2014 Yamaha FJR1300A Name: Dan	Before I worked on the transmission change over I needed to design a new front engine mount. The ZG1000 engine was a stressed member of the frame and the cylinder head was mounted to the frame as a result (same as the Ninja 900 which this motorcycle was derived). The ZRX engine was not mounted this way. I designed a new engine mount using my 3d CAD system. Attached Thumbnails

12-09-2020, 08:12 PM	#7
bergmen Veteran Join Date: Feb 2006 Location: Ukiah, California Motorcycles: 2014 Yamaha FJR1300A Name: Dan	I was able to acquire a spare Concours frame to use for developmental purposes so I could leave my Concours unmolested during the engineering of this conversion. Attached Thumbnails

12-09-2020, 08:14 PM	#8
budman General Menace AMA Life Member #203453 Highway Aviator Founding Member Top Percent Poster Community Contributor + BB Moto Junkie Join Date: Apr 2002 Location: Palo Alto, Ca. Motorcycles: Keep me rocking life Name: Budman	Sweet. Drilling the hole had to be the deal. Screw that up and start over.... with new cases. I am impressed. __________________ Your friendly neighborhood.... Budman BARF Terms of Service Be a BARF Contributor! Support those that support Barf! BARF Sponsors 1Rider introduction on KFOG Bone heads and bikers podcasts Racism and RIP threads on Barf - FYI Barf is more than a dub dub dub dealio Godspeed Mom Pit Ho Godspeed Nicky #69 Hoho AMA #203453

12-09-2020, 08:16 PM	#9
bergmen Veteran Join Date: Feb 2006 Location: Ukiah, California Motorcycles: 2014 Yamaha FJR1300A Name: Dan	The Concours shift drum, shift shafts and gear indexer arms mounted in the crankcase without modification. Here I am doing a complete function test of all of the transmission components in the ZRX case. Attached Thumbnails

12-09-2020, 08:25 PM	#11
bergmen Veteran Join Date: Feb 2006 Location: Ukiah, California Motorcycles: 2014 Yamaha FJR1300A Name: Dan	More tomorrow, I'm heading to bed...

12-10-2020, 02:04 AM	#12
Pushrod Veteran Join Date: Feb 2008 Location: Central Florida Motorcycles: VTR, R100RS,CB500 Name:	Drilled into a case, got it square and straight, with a hand-held drill? That qualifies for admiration.

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