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Old May 30th, 2019, 11:24 AM   #1
fastfrank
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Motorcycle(s): 1999 ZRX1100, 1983 GS1100ES, 1978 KZ750 Twin, 2013 GW250

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Old-timer newbie

After some 13 years of medical issues and bikes sitting idle, I’m in the process of getting back in the saddle again.

I’m resurrecting two big bikes, a 1999 Kawi ZRX1100 that didn’t run well before sitting, and a 1983 Suzi GS1100ES that had been drag-racified before I got it, but ran pretty well. Needless to say, neither runs well right now after hibernation, but I’m getting there. My old Kawi KZ750 twin, on the other hand, runs just fine.

I’m in Central NY (closer to Canada than the the city), after moving here from the San Diego / Escondido. I used to spend a fair amount of time up at Palomar Mt., (I’m sure some of you know the place) did some track days at Willow Springs on an RC51 (that I sold along with my Hayabusa after having twins because I was going way too fast), got to run around Laguna Seca thanks to Honda after World GP, and have owned all manner of bikes over the years.

So, I got here after trying to get my ZRX throttle housing back together, after neglecting to take pictures, and finding links from the EX500 site. I really appreciate the help.

So, I am nearing completion on my ZRX, after finding my #3 carb body broken at a corner under the cap (my only on-street accident ever was after buying this bike used in Chicago and riding it back to San Diego, when a lady pulled out in front of me in the rain, I bottomed out the front fork and separated my shoulder). Of course, there was the more general gunk in the pilots, etc. Just got the carbs reinstalled, currently, I’m running on a stand while waiting for a new battery, after flushing all fluids, retorquing everything I’d touched, putting on a XZ11 rear wheel with a fresh tire, etc. The hardest part (not that removing carbs is fun), was cleaning out the tank... just takes multiple steps and time and lots of manual shaking (using a chain in it - beats nuts & bolts).

I’m anxiously awaiting my battery, and should be on the road late this week !!!

My GS1100ES has Mikuni VM33 smoothbore race carbs on it, and while they aren’t hard to work on, I sent them off to a specialist and they are on the way back now. I still need to drop the oil pan to make sure I’ve cleaned out all gunk, so the oil pickup / filter actually sucks oil. I’m putting new Progressive shocks and front springs on it, and raising it back up to more streetable levels... it has an extended swingarm and was seriously lowered... not my thing. I have the stock swingarm, and I might swap it back.

So, that’s the story. Thanks again for the throttle help.

(Not so) fastfrank
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Old May 30th, 2019, 11:56 AM   #2
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Old May 30th, 2019, 02:02 PM   #3
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Greetings Frank!

So 13-yrs ago at Willow Springs.. We probably cross paths back then!
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Old May 30th, 2019, 02:21 PM   #4
fastfrank
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Motorcycle(s): 1999 ZRX1100, 1983 GS1100ES, 1978 KZ750 Twin, 2013 GW250

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Willow Springs...

"So 13-yrs ago at Willow Springs.. We probably cross paths back then"

Probably more like 16-18 years, but we may well have. My RC-51 was a 2000, if I remember correctly (really, really nice bike, btw, but always felt like you were going half-fast with the weird vibes from the twin).

BTW, that must've been 2001 at Laguna Seca, since I got Colin Edwards' autograph... I think.

About to take a ride on my little GW250 that I bought to get my twin boys started. I sorta have my eye on the newer 400 Ninja as an upgrade for them. Of course, they're looking at 600-650 class...

I was going to ask about recommended upgrades from a GW250, but this being a Kawi site, I'd probably get answers like "skateboard".
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Old May 30th, 2019, 09:48 PM   #5
fastfrank
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Thanks for the warm welcomes

Appreciated
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Old June 2nd, 2019, 07:25 AM   #6
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Old June 3rd, 2019, 07:32 PM   #7
fastfrank
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Angry Good news, bad news

Finally! I got my ZRX running and took it for a 15 minute ride, which went very well, aside from popping on deceleration, fading rear brakes, and throttle cables that still need some adjusting... so, some minor work on adjustments. It had better acceleration and idled better than it ever had previously since I’ve owned it (I guess replacing a broken carb can do that).

Fast forward a couple hours, and I’m about to show the bike to some friends, and then turning it around in the garage, I dropped it over on its right side and broke the front brake lever and signal lens.

While I have the replacements on order, it’s painful to wait after finishing all that work over several weeks.
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Old June 3rd, 2019, 09:19 PM   #8
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I hate when that happens!!!
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Old June 4th, 2019, 12:44 AM   #9
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welcome

had a killer zrx that i crashed hard on and totalled. man do i miss that one
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Old June 4th, 2019, 09:21 AM   #10
fastfrank
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Name: Frank
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Motorcycle(s): 1999 ZRX1100, 1983 GS1100ES, 1978 KZ750 Twin, 2013 GW250

Posts: 15
Crashed ZRX

I hope you didn’t sustain as much damage as your bike...

My only on-street accident was with this bike.
I bought it used from a guy in Chicago when I lived in San Diego.
On the second day riding back, a lady pulled out in front of me in the rain... I bottomed out the fork, which pitched me over, and separated my shoulder.
Had a broken right peg, but it was rideable. I stopped to get Ibuprofen then got a motel room, which I couldn’t stay in long with the pain, so checked out and eventually made it back home. Was challenging to get through the Tehachapi area with the wind and 18-wheelers intermittently blocking it.

The only remaining souvenir from that episode is road rash on the front fairing.

I’ve since adjusted the forks so I won’t bottom out again.
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Old June 5th, 2019, 09:54 AM   #11
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Old June 6th, 2019, 08:03 AM   #12
fastfrank
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Name: Frank
Location: Upstate NY
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Motorcycle(s): 1999 ZRX1100, 1983 GS1100ES, 1978 KZ750 Twin, 2013 GW250

Posts: 15
Hoping to ride today

I discovered that I could temporarily steal the brake lever from my boys' GW250 to fit the ZRX (which surprised me). I've already installed the new turn signal lens, so I'm ready to get back out on the road for another test.
Looks like the rain has let up for awhile, so I'm going to ride!
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Old June 6th, 2019, 07:06 PM   #13
fastfrank
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Name: Frank
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Motorcycle(s): 1999 ZRX1100, 1983 GS1100ES, 1978 KZ750 Twin, 2013 GW250

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First real ride of ZRX

Success: I managed to get the ZRX out for a rather spirited ride this afternoon, with my Son tagging along with the 250, just in case.

Probably still some minor tuning to do, but it is running really well... more acceleration than ever.

Later on, both of my 20-year-old twin boys took it out for a spin - first time they've ever been on a liter bike. Needless to say, they came back impressed and wanting more.

Now we're talking about going bike camping somewhere, now that we have three working bikes.

I'm waiting to get my VM33 race carbs back from the expert, and may actually get the GS1100ES (dragbike) ready for the street next week, if all goes well.

Everyone keep the rubber on the bottom.

Cheers
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Old June 7th, 2019, 10:36 AM   #14
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Old June 7th, 2019, 01:10 PM   #15
fastfrank
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Name: Frank
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Motorcycle(s): 1999 ZRX1100, 1983 GS1100ES, 1978 KZ750 Twin, 2013 GW250

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Thanks

Thanks
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Old June 7th, 2019, 01:17 PM   #16
fastfrank
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Name: Frank
Location: Upstate NY
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Motorcycle(s): 1999 ZRX1100, 1983 GS1100ES, 1978 KZ750 Twin, 2013 GW250

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Nice ride

We managed to get three bikes on the road at once, and rode through Clinton, NY to Waterville, where we had a great lunch at Roc Star, then found some minor twisties on hwy 315.

I managed to miss a deer that jumped out in front of me, and a tourist in a car in the middle of the road stopping to see the river right at my favorite “25 MPH” turns.

First time we got three bikes out together. Lots of fun.
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Old June 7th, 2019, 05:58 PM   #17
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here is my zrx 1200 that i crashed.
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Old June 7th, 2019, 06:02 PM   #18
fastfrank
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Name: Frank
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Motorcycle(s): 1999 ZRX1100, 1983 GS1100ES, 1978 KZ750 Twin, 2013 GW250

Posts: 15
Your crashed ZRX

Should I assume that was a "before" picture, or was this a rebuild?

Very nice looking bike - I haven't seen the (Holeshot) exhaust painted like that before. And the engine covers, even. Very nice.
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Old June 8th, 2019, 12:17 AM   #19
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Quote:
Originally Posted by maverick9611 View Post
here is my zrx 1200 that i crashed.
I like the purple accents!!
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Old June 8th, 2019, 05:45 AM   #20
maverick9611
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it was one of a kind shape shifting powdercoat. naturally i used zzr cases for pop

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Old June 8th, 2019, 05:47 AM   #21
maverick9611
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left pic is when i started, right pic well...
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Last futzed with by maverick9611; June 9th, 2019 at 03:43 AM.
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Old June 8th, 2019, 05:56 AM   #22
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my crash as done by beantown from zrxoa
http://www.zrxoa.org/forums/showthre...-Boy-went-down!
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Old June 9th, 2019, 12:55 PM   #23
fastfrank
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Name: Frank
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Posts: 15
ZRX stuff, ATGATT

Thank goodness for ATGATT - I survived my fall with a separated shoulder, but would've been in pretty bad shape without the gear - my boot was worn through, my glove was worn through, my cordura riding pants wore down to the armor, same for a sleeve and the side of the jacket. Wore my front brake lever down an inch like a grinding wheel.

Sounds like you had an ankle problem, but were lucky overall. Hope you stay that way.
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Old June 9th, 2019, 02:12 PM   #24
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Old June 9th, 2019, 04:20 PM   #25
fastfrank
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Maverick - I see you are in Augusta...
My parents were from Augusta, and I still have lots of kin there, including a sister in Aiken... man, it gets hot & humid there, almost like Houston. A guy over in Rock Hill has my VM33 carbs just now; I dropped them off on my way to GA to see family.
I’ve lived in Columbia & Sumter, & Athens (at UGA), in your general environs.
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Old June 9th, 2019, 05:46 PM   #26
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yup, i like it. 4/5 hours from mountains.
daughter goes to uga, starting her junior year.
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Old June 15th, 2019, 10:40 PM   #27
fastfrank
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Getting there

Been riding my resurrected ZRX with reworked stock carbs, etc.
I still need to sync the carbs, and adjust the valves, and apparently richen my pilot jets (or take a few discs out of my Supertrapp), since it is popping at idle and decel. Above the pilot range, however, it is dialed in and pulling hard, with no flat spots. Getting there. But I’m already thinking about swapping in my CVK40 carbs (36 is stock), and I’m definitely dropping in my ZX11 cams when I do the valve shims.

I broke down and ordered new VM34 carbs for my KZ750. I just don’t get along with the weird BS38 stock carbs that install jets in the float bowls. I know most of my issues are probably due to a deteriorating “Kreem” treatment of the tank before I bought it... with the ethanol in the gas, and an occasional dose of fuel treatment, it is not in great shape. I’m actually running two inline filters in series, but they don’t seem to catch the emulsified gooey gunk that will clog the pilot jets and probably other orifices. If I keep a high idle, it actually runs pretty well, though (for now).

Been trying to install a new +1 front sprocket on the GW250 (Inazuma), but I couldn’t break loose the 30mm nut, even with a long breaker bar... probably have to heat it.

Just got the VM33 smoothbore carbs back together for the GS1100ESD. Waiting to put them back in until I get the new stator installed (had the wrong gasket), and get a new oil filter and spring. The oil filter cover, which was plumbed for an oil cooler, I just managed to lose the nuts for. I do have some wingnuts that size, though... may as well. I also have a lost Progressive shock. Driving me nuts.
Still deciding whether to switch back from the extended swingarm to the stock one. Then I have a big rewiring project for it planned. Lots of work.

Getting there.
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Old June 16th, 2019, 11:27 AM   #28
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Old July 6th, 2019, 08:18 AM   #29
fastfrank
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Name: Frank
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Motorcycle(s): 1999 ZRX1100, 1983 GS1100ES, 1978 KZ750 Twin, 2013 GW250

Posts: 15
ZRX twists and turns

So, the ZRX has taken some interesting and frustrating twists along the way... apparently there was some white silt that wasn't completely cleaned out of the tank (even after a week of prep, and gas flushes), that ended up causing flooding on #3, and left a small pool of stuff in each carb's float bowl. I had even used a 40 micron inline filter, so this stuff is really small. It can be blown away like a fine powder. The jets actually don't look bad, but there is still cleaning to do.

Looks like a carb re-re-build is in order - BUT...

I have an "extra" set of larger 40mm carbs from a ZX11, and just happened to also have a set of cams from the same big Ninja.

I have already swapped the cams in (making plenty of mistakes along the way), I've installed the 40mm carbs, and I've adjusted valves while doing the cams.

I decided to coat the tank to avoid more carb issues, and went with the 3-part Bill Hirsch product. You end up with a very durable vinyl surface inside.
I need one more day to let it cure/dry, and then the tank goes back on.

I'm happy to say that the bike is running really well, on the stand with an IV drip. I got the carbs synced up (actually the bench sync was dead-on), but now I'm troubleshooting a fan problem - likely nicked a wire while doing the cams (I know they are all plugged back in).

I should be back on the road in about 2 days - can hardly wait. I'm also looking forward to seeing how it performs now - on paper, it should be making about 135 HP (not that I really need it these days). As a rider, I'm only half-fast these days, anyway.

I guess the moral of the story is:

1) always go all the way when prepping a tank
2) take advantage of downtime to make it better and faster (lemons...)
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