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Old 12-10-2020, 07:37 AM   #16
bergmen
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The oil systems between the Concours and ZRX1200 were identical with one exception. Since the ZRX did not have a bevel gear case to lubricate, the oil from that passage was diverted to an oil "spray bar" running spanwise in the transmission. I needed to plug that to divert the oil to the predrilled passages for the bevel gear case.

There were a couple of options to consider. One was to tap the hole on the inside of the case and install a very short hex set screw to plug the hole. This would have been ideal but I did not want to risk getting chips down into the oil passage that would be very difficult to remove. So I opted to plug the end of the "spray bar" and re-install it into the transmission.

Dan
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Old 12-10-2020, 07:52 AM   #17
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I need to go back to the beginning for a minute. Before I could start this project, I needed donor parts from a healthy ZRX. I found that there were engines available (hooligans at the time were totalling these here and there making parts available). But I did not want to have to trust an engine from a crashed bike not knowing if it had laid on it's side with the throttle wide open before getting shut off.

So I did the next best thing and found a nice clean 2003 ZRX an hour south of me and bought it for $4000 (I ended up selling all of the unused ZRX and Concours parts for about the same so it was a wash).

I built two plywood roll-around platforms to do the surgery. One of them was used for the ZRX and the other ended up on saw horses for the engine/frame/ engine mount work.
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Old 12-10-2020, 07:58 AM   #18
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In addition to all of this, there was an excellent source of brand new Concours parts I could draw on. An outfit in Texas got a contract to build 100 police outfitted Concours for the Egyptian armed forces. Part of that contract was to also supply 30 complete new engine assemblies as spares. Kawasaki had no means of supplying these so they bought 30 extra Concours motorcycles and harvested the engines out of them. They sold the rest of the parts for pennies on the dollar. I bought a bunch of parts (you'll see later in this saga) along with two brand new frames (frame numbers ground off and officially removed from registration and were to be scrapped). I got these free for the cost of shipping from Texas.
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Old 12-10-2020, 08:18 AM   #19
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I needed a transmission and bevel gear case from a donor Concours so I would not have to tear mine apart for this (I wanted to continue to be able to ride during this project not knowing how long it would take).

One of the issues plaguing the Concours was a tendency to hydrolock due to a lousy petcock design. Often, owners would just remove the pranged engine and go find another to replace it. So, it was pretty easy to find one (a 1994 IIRC) and I offered to buy basically everything aft of the crankshaft (transmission, all shift parts, bevel gear case, clutch hub, etc.). The owner gladly obliged and sent me a box of parts.

Here I have just unpacked the donor parts.
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Old 12-10-2020, 09:17 AM   #20
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did the ZRX transmission not need the lubrication from the spray bar? maybe i'm misreading but if they're otherwise identical transmissions why does the ZRX need more oil on that area?
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Old 12-10-2020, 10:15 AM   #21
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did the ZRX transmission not need the lubrication from the spray bar? maybe i'm misreading but if they're otherwise identical transmissions why does the ZRX need more oil on that area?
Spray bars are a good thing but after lots of thought on this, I figured this was a convenient way to deal with the oil supply that typically would go to the bevel gear case.

The oil system for the transmission in both bikes was identical, pressure fed to the roller/ball bearings on the input/output shafts as well as all of the gears on both shafts. I figured if the Concours could live happily without a spray bar then the Concours transmission would be okay without one as well.

Also, I think that Kawasaki realized that the ZRX was going to be owned by hard riders (wheelies, max acceleration, stoppies, etc.). That's okay, I was going to be a much more subdued rider even though I was going to have a lot more horsepower and torque. Here is a comparison of the two (horsepower/torque curves).
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Old 12-10-2020, 10:30 AM   #22
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thanks!
calculated risk i totally get it
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Old 12-10-2020, 10:43 AM   #23
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thanks!
calculated risk i totally get it
Also, I needed that oil supply for the bevel gear case or this project would have been dead in the water. It worked out fine in the end.

I made a commitment early on (to myself and my wife who was not all that thrilled about taking over the garage on some wild adventure) that if some brick wall showed up, I would back out, put everything back together as it was and sell the ZRX. I made a point of not modifying anything that would prevent it's return to normalcy. My engine mount was a bolt-on affair even though I considered modifying the ZRX head to attach it to the frame (I didn't trust that concept for several reasons).
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Old 12-10-2020, 10:58 AM   #24
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Moving to the bottom of the engine for a minute, I needed to have a Concours oil pan installed so my stock Concours exhaust would fit underneath. The ZRX pan would not allow this. Here is a comparison of the two.

In addition I mounted my spin-on oil filter adaptor kit (in gold) I designed and patented (for the Concours but would also work on a number of other Kawasaki motorcycles including the ZRX).
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Old 12-10-2020, 11:13 AM   #25
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Back to the engine mount parts I designed several parts with pilot holes only so I could accurately position the final attachment holes "on assembly". I positioned the engine in the test frame carefully, attached all of the engine mount parts and began to locate the final holes. Once located, I removed them and went over to the drill press to drill and then tap as necessary.
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Old 12-10-2020, 11:20 AM   #26
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Once drilled and tapped, I assembled the mount on the test fixture for a final fit check. Then I sent the aluminum parts out for hard anodizing and then did the final assembly to the engine.
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Old 12-10-2020, 11:27 AM   #27
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Now we are getting serious. It is time to move over to the Concours and start the transplant surgery. This is when I really felt this was going to work.
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Old 12-10-2020, 12:03 PM   #28
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Uhh.....you are some kind of egghaid. Very impressive

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Old 12-10-2020, 12:21 PM   #29
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Uhh.....you are some kind of egghaid. Very impressive

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Gearhead might be closer. My Dad (machinist/millwright from the 30s, aircraft tooling specialist later) taught me well.

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Old 12-10-2020, 03:37 PM   #30
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I need you to come up and work on my 1959 Jeep CJ5 that the previous owner "modified"

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