ZG1000 in GPz900 clothing

[Chrome Megaphone]

I finally got my 1985 Concours/Ninja project running again after several setbacks which included a blown engine due to not replacing the rod bolts after a 2mm overbore with ZX11 pistons on 88-89 ZX10B rods and oil burning from wobbling valves elongating the seals because I couldn't resist tear dropping the guides during head porting. Lessons learned.

Anyhow, now with a re-ringed stock bore and eBay stock head wearing the GPz900 cams, carbs (Dynojet kit), and Vance & Hines advanced ignition timing plate she's not as spooky explosive as before but still fast enough and much more controllable. Yesterday after having it inspected I pulled out onto the four lane road with enough throttle to induce a power slide which was easily recovered from.

[Big Red]

That's pretty slick. Take a lot to mount that bodywork?

[Chrome Megaphone]

It's a semi-bolt on affair that required some shade tree ingenuity to mount the ZG oil cooler, aftermarket GPz radiator, and securing the rear undertray.  Basically the oil cooler lines are a tad short so it goes behind the lower frame mount with longer bolts serving as studs.  AliExpress radiator needed two .5 inch rubber bushings, longer bolts & nuts, and a trick to get in there because the end tanks will interfere with the frame.  I couldn't find a GPz lower tray frame that goes under the engine so again thick bushings & longer bolts to the oil pan worked out.  The windscreen is an AliExpress part, it's a sport touring style slightly taller.

I didn't keep track of cost, you know how these things add up.  It probably would have been better to just buy a GPz900 but wrenching on bikes and cars are a hobby of mine.  Keeps me sane.

Here's my 1986 GL1200. 

[berna1201]

Good morning;
Nice modifications, I like 

[Stasch]

Nice job.  Me likey muchly. 

I didn't keep track of cost, you know how these things add up.  It probably would have been better to just buy a GPz900 but wrenching on bikes and cars are a hobby of mine.  Keeps me sane.

I consider motorcycle projects an investment in myself, the satisfaction of a job well done that bring many new things learned along the way.   

[Chrome Megaphone]

Thanks all for the positive feedback 
I forgot to add a ZL900 Eliminator bevel gear was swapped in which really gets it off the line. 

[Chrome Megaphone]

A few more pics.
Manual calls for dropping the engine for cylinder head r&r but I found zip tying the second row head bolts together with the bottoms flush with the mating surface allows getting it in and out.  These bolts are blocked from removing by the frame with the head in place. Huge time saver.

Front and rear rotors are AliExpress, so far no warping.  Wheels were cleaned then sprayed with 2K Clear Coat bodywork Rust-Oleum Industrial Black topped with 2K.

If I put on the ZRX1100 front end I have sitting in the garage the front forks, wheel and brakes will go on sale.

[berna1201]

what is this screw ?

[Chrome Megaphone]

The petcock stopped feeding on me causing the engine to die on a two lane road in heavy morning traffic.  I coasted off into an uphill gravel driveway and dropped it, breaking the peg.  That's a temporary fix that's turned permanent because apparently the left peg breaks on every drop and they're near impossible to find.

Petcock has been rebuilt but I sure can use that peg if anyone has one.

[berna1201]

Damn then, it welds well, I have already repaired 

Both parts were broken, as it was on the sidecar it is no longer foldable.

[Chrome Megaphone]

Nice work and far beyond my abilities.

[Chrome Megaphone]

Here's the overbored engine autopsy.  Two of the stretched rod bolt are on the case, they came apart like taffy.

[berna1201]

Hello
Sacred damage, personally, I reuse the screws too and I never had this problem, I think rather that the condition of the bolts is not the cause, but the result, I will look more on a problem of lubrication.

The 3/4 connecting rod heads are lubricated by the small metal tubing and it causes problems.

http://berna1201.over-blog.com/2020/03/graissage-moteur-gtr-1000.html

@+
Bernard

[connie_rider]

I went into Ebay and found some left footpegs and brackets.
Unfortunately for the $$ they want for the used parts you can almost buy the new. All shown here.

https://www.ebay.com/sch/i.html?_from=R40&_trksid=p2499334.m570.l1313&_nkw=left+foot+peg+zg-1000&_sacat=10063

I'm picking up a crashed C-10 next month (for the engine).
If it has the left peg, I'll let you know.

Ride safe, Ted

PS: Do you still have the over bored cylinders? If it's not damaged, I might be interested.
I have the needed pistons and rods for a 1052 and have been thinking about doing this mod for years.

[Chrome Megaphone]

I went into Ebay and found some left footpegs and brackets.
Unfortunately for the $$ they want for the used parts you can almost buy the new. All shown here.

https://www.ebay.com/sch/i.html?_from=R40&_trksid=p2499334.m570.l1313&_nkw=left+foot+peg+zg-1000&_sacat=10063

I'm picking up a crashed C-10 next month (for the engine).
If it has the left peg, I'll let you know.

Ride safe, Ted

PS: Do you still have the over bored cylinders? If it's not damaged, I might be interested.
I have the needed pistons and rods for a 1052 and have been thinking about doing this mod for years.

It was destroyed in the two affected cylinders.

[berna1201]

it is obvious in the photo

[Chrome Megaphone]

A few night pictures to show the led lights and reflective flame and Ninja script.  Looks better than I anticipated.
I'm thinking about putting it on the market since I have a Gold Wing 1200 for traveling the Kawasaki isn't ridden very much (I need my car for work).  Since this is literally a remanufactured motorcycle it hurts even thinking about selling it.  I've put so much into it cost wise and on a personal level.

[Freddy]

Keep it - I would.  Probly not worth much on the open market.

[Chrome Megaphone]

Yeah and I'll regret it like every other bike I've let go.  I'll pick up some Sta-bil 360 marine to pickle the fuel, it's the best from what I've read.

[Big Red]

Yeah and I'll regret it like every other bike I've let go.  I'll pick up some Sta-bil 360 marine to pickle the fuel, it's the best from what I've read.

If they offer no ethanol fuel in your area, that's the stuff. Or 100 octane race gas. Expensive, but keeps much better than regular fuels. I just drained a tank with 3 year old mix of 93 (with ethanol) and 100 race gas, and the stuff was still useable. I was shocked.