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Old 12-09-2020, 01:01 PM   #1
bergmen
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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
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Old 12-09-2020, 04:44 PM   #2
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Originally Posted by bergmen View Post
...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
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Old 12-09-2020, 06:52 PM   #3
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The conversion to a shaft drive alone is worth hearing more....
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Old 12-09-2020, 07:46 PM   #4
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I agree.
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Old 12-09-2020, 07:51 PM   #5
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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:
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Old 12-09-2020, 08:08 PM   #6
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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.
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Old 12-09-2020, 08:12 PM   #7
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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.
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Old 12-09-2020, 08:14 PM   #8
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Sweet.

Drilling the hole had to be the deal. Screw that up and start over.... with new cases. I am impressed.
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Old 12-09-2020, 08:16 PM   #9
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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.
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Old 12-09-2020, 08:25 PM   #10
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Originally Posted by budman View Post
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.
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Old 12-09-2020, 08:25 PM   #11
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More tomorrow, I'm heading to bed...
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Old 12-10-2020, 02:04 AM   #12
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Drilled into a case, got it square and straight, with a hand-held drill?

That qualifies for admiration.
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Old 12-10-2020, 05:37 AM   #13
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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


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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.
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Old 12-10-2020, 06:58 AM   #14
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Old 12-10-2020, 07:18 AM   #15
bergmen
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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
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