ZG1200 Experience 99

[Nails]

These sure are ugly with all their guts-n-stuff exposed.

[cbrfxr67]

True Nails! i bet the neighbors who saw me putting around last night were thinking 'what the hell is that,...' hahah

That sound turned out to be,... Broke bolt and washer rattling around in alternator coupling.






Used my handy stethoscope,....one of the cheap and great tools I've picked up over the years that actually helps figure stuff out.

After sewed that up went for a putt around the neighborhood. Carbs don't 'feel' right yet but no stalling and powered up on throttle. I'll keep messing with it,...

[cushman eagle]

True Nails! i bet the neighbors who saw me putting around last night were thinking 'what the hell is that,...' hahah

That sound turned out to be,... Broke bolt and washer rattling around in alternator coupling.






Used my handy stethoscope,....one of the cheap and great tools I've picked up over the years that actually helps figure stuff out.

After sewed that up went for a putt around the neighborhood. Carbs don't 'feel' right yet but no stalling and powered up on throttle. I'll keep messing with it,...

I just fixed a loose bolt/ rattle in my alternator a month ago.Simple to fix,not so simple to diagnose.

[Nails]

So decided to swap the fuel filter,...man that's a bugger to get to! Had to take half the bike apart to get to it!

Pretty sure I got to mine from the side. Been a while, but I think I just had to take the radiator reserve tank off. I know I replaced it and never taken all that crap off the top.

Maybe I did this when the carbs were off. Dunno. Got Can't Remember Sh*t (CRS) disease.

Definitely good to go through these things once or twice a century.

[Nails]

I didn't have time to respond to these at the time. But what the heck, the board is dead now anyway.

Pulled carbs from both bikes. Needless to say, that was fun. I found pushing the airbox boots into the airbox gave me enough room.

Pushing the boots into the airbox to get carbs off helped but then of course I couldn't get them out.

I've had the carbs off-and-on at least a dozen times. I finally resolved to leave the boots in the airboxes where they belong and just manhandle the carbs between them and back into place. I used things like a long screwdriver and bad words, dealt with each hang-up as it comes up, and steady ahead by jerks.I think that's less mangling than screwing with getting them back out of the airboxes. Either way, it'd sure be a bummer to crack one.

I'd also recommend using a slightly longer fuel line -- makes life easier for both the carbs and the filter. I try to attach the fuel line to the carb gallery when the carbs are half in and I can still see what I'm doing. For me, that fuel line is the hardest part -- a large roach-clip helps. (The throttle return cable is a close second. I'm still planning to dump the throttle cancel switch for the cruise and see if that makes life easier. I'd move that switch to the cockpit, where I'd actually use it.)

I'm surprised you didn't find lots of rotten rubber/plastic. I needed lots of those expendables.

For this job, I sprang for a cheap sonic cleaner, less than $100 as I recall. I've used that a million times since then. Definitely paid for itself.

I wish I knew Carl Leo's secret for polishing the carb slides.

[doug of so fla]

Tip: Too pull rubber boots thru air box openings:: Lube ends of boots and air box openings with silicone grease THEN wrap a string around the grooves on the ends of the boots THEN pull strings and boots thru air box openings. pull strings out by one end. WORKS!!

[cbrfxr67]

Good tips! Appreciate that! And cushman eagle haha

Not much to report. Ran it a bit yesterday and sounded good. Worked on stripping parts bike down.


This was as far as I got. Any tips on getting swingarm off? I'll have to go read the manual for that one unless someone can
help me with a quick how to get that off with more than curse words

[triton28]

Section 12-12 of the Service Manual makes it look so easy to remove the swing arm shafts but in reality rust usually forms a ring around the shaft in the space between the bearing seal, and the frame gusset the shaft passes through, thereby blocking the shaft from pulling through the gusset.
This ring of rust around the miniscule exposed portion, as well as some rust in the gusset around the hidden portion of the shaft, will stop the shaft dead in it's removal tracks. Try to get a string/strand of steel wool, or some other form of abrasive cordage wrapped and rotated on the rust on the exposed portion of the shaft between the bearing seal and the frame gusset. Use lots of penetrating oil and eventually the rust will dissolve and the shaft will loosen and be able to be removed out of the gusset using the 8mm bolt puller trick shown in the manual.
Dave

[cbrfxr67]

https://youtu.be/jZRplU_e4H8

I can't figure out how to post video,...

Reorganized to be able to find everything I need to start putting it all back together. Was two piles of bike parts and now got it sorted out nicely. Messing around with the radio although it sounds kind of flat. Not sure how the sound is supposed to be, if it's pretty good or just 1986 average?

Hopefully get progressive springs for front ordered and also 412-4221C for rear and start sewing this up.

[cbrfxr67]

Everybody likes new parts,...


neasy enough and a beautiful upgrade





Got my front springs in yesterday. I think I\'m going to weld up those pea holes for the air ride. Was thinking to tap them and put a screw in but welding would be easier and forget about it.<br/>\n<br/>\nFinished stripping parts bike down. Was glad to haul that frame to the curb for the scrap guy to pick up. Maybe clean up the engine and try to sell it, plus everything else we don\'t need,...<br/>\n<br/>\nSeems to be running well although the throttle cable is not smooth. Tried lubing it and still crappy. I disconnected one side and am thinking of yanking that whole assembly out and replacing it with two cables. Anybody done that?

[Nails]

Regarding the forks, I used gasket seal, gasket material, and hose clamps. If I had it to do again, or next time it's apart, I'll rig an air bleed-off valve. Regarding cables, I assume you mean the cruise cancel switch. Next time that's apart, I'll hook the harness to a cancel switch. Pretty sure the tape/radio switch would work -- if you dump all the radio crap.

[cbrfxr67]

Neil, I had to glue my fender a couple of months ago while evaluating the break of my fender guard to rough roads. It took but I probably need the shims there again so it doesn't rebreak. I can sympathize with you. Otherwise, your bike seems to be tolerating the trip rather well. As for pilot screw adjustments for us flatlanders, I haven't had to do that. Rode the Voyager back in 2015 in Arkansas hills without having to make any adjustments. Never had to adjust the pilots either on my ZRX1100 that I rode several times in Arkansas. Guess I wasn\'t at a high enough altitude. I pray you have a good noneventful ride the rest of the way. We are looking at a terrible heat wave here.

[cbrfxr67]

Nails, air bleed off valve is a good idea. Little more than I want to put into that though. I figure I can back that little hole with some copper and weld grind, be done with it. Well hopefully. Probably warp it or forget to turn my heat down &amp; blow a huge hole in it,...haha got my springs in so time to get started


and that was as far as I got last night. Reference for anyone who might be looking for lengths

[cranky]

the gizzies ya take out will make room for the Xtra spring.. and now ya<br/>\ncan prepare to take another 3" off yer shield... if ya like to look over it... BTDT

[SgtSlag]

Just in case you missed this tidbit... No air assist is required with the new Progressive Fork Springs. Some folks add a few pounds (1-3 pounds, hand pump only, to make it even stiffer. Your bike, your choice. Cheers!

[Nails]

Nails, air bleed off valve is a good idea. Little more than I want to put into that though. I figure I can back that little hole with some copper and weld grind, be done with it. Well hopefully. Probably warp it or forget to turn my heat down &amp; blow a huge hole in it,...haha got my springs in so time to get started


and that was as far as I got last night. Reference for anyone who might be looking for lengths

I had a mechanic put in bushings and all, total rebuild with the Progressives. He offered to MIG weld the holes, so I don't think warpage is a huge risk. I think the airlines significantly increase the headspace, which in turn affects oil level recommendations you'll find here. I also think that the stock tubing could make the headspace a little mushy. (Maybe Don will chime in.) By eliminating all this, I went with the lower stock oil levels. (I'm a committed fan of Dextron III for fork oil -- the viscosity works great, and I like the high detergent level. Dextron III also brought the stock shocks back to life, and I feel no need whatsoever to upgrade them until they start leaking.) Hooking up a bleed-off valve (just a Schrader) to the existing manifold (between the forks) would be easier than screwing with welding that hole. Next time I'm in there (maybe to try RaceTech cartridge emulators) I'll unplug the holes and braze a small, hard valve affair. Just saying that I'm glad I didn't nuke the holes or toss the manifold.

[cbrfxr67]

Appreciate the tips sgtslag & cranky,.. Always good insights. Thanks Nails. I did go ahead an weld them up last night. Been lacking on time lately,... WIll spray little clear over this to keep it from rusting again.

Hopefully get these done tonight

[cbrfxr67]

Looks like I lost a few posts,.... let's see,...

made a jack adapter,....


worked great for front end


swapped out forks and front tire,...bled brakes


put on fairings,...so i dont have to mess with them anymore just tuning




got all my lights working


wondering if that left bar is whopped, still haven't got the other one out yet but i will


have corbin to recover but stock seat is going back on

max urls

[cbrfxr67]

since it is so comfy,..actually since it isn't in bad shape and i dont have time for corbin yet


working on tuning,..having problems with surging,...pilots dont really do anything,...
still runs and actually when i took this pic i just came in from a good ride which was a blast.


Pulled carbs again last night. At least I'm getting good at it. My buddy thinks I have an air leak somewhere but if the pilots don't really do anything, I'm thinking gas is getting past the orings. They do look pretty crappy so I ordered them and should have in a couple days. Other than that, looks good inside.


Will paint those lids and finish up plastic weld repair on dummy tank. It had four tabs broken. I started on it but haven't finished sewing it up. Waiting on orings will give me a good window to do that and hopefully get my 500 rolling and this followed me home last weekend, so maybe get some time to start figuring out what's wrong with it. 1k though. I think I did pretty good

[cbrfxr67]

(crickets)(crickets) where is everybody,...ah well,...


carbs back together,...


had a minor delay as a neighbor came up with this gsxr 1000 k5 and I can't resist a bike that won't run. Turned out to be fuel pump was trashed. Got that swapped and tank cleaned, figured out and it cranked up. Almost lost the rear end hotdogging on those old crappy tires . I think he said that it's been sitting for a number of years. Fast bike,...would love to have one.


Rolled her back in for carbs reinstall,..and airbox hell


Hours later I came to, sweating and dazed! Looked down to find this,.... "This airbox laid to rest in dedication of all those before who wanted to destroy it in utter frustration but managed to hold onto their sanity." Great now what am I going to do,..wasn't somebody talking about a 115 and 45 w pods on the forum,....?


if this was project binky I'd've had some tea while staring at this,..


hmmm
Flame on!