Kawasaki Concours Forum

The C10, aka Kawasaki Concours - The Original => The Bike - C10 => Topic started by: sport rider on December 28, 2018, 10:20:25 AM

Title: Cafe Build of a C10
Post by: sport rider on December 28, 2018, 10:20:25 AM
I thought I'd start a separate thread than my intro thread to post more about my cafe project.  attached is a prototype pic, but I still have a LONG way to go before I call this one done.  I picked up a $350 donor bike for starters.  it showed signs of being dropped like the fairing cracks at the mirrors, and some minor cracks on the side panels.  however, no signs of  being down hard.

I have a ZRX front end and meanstreak rear wheel to set it up with 17s front and rear.  I'm using the stock ZRX bars for now, but will likely replace those as I get closer to completion.

for now, I plan to use the stock tank.  that might change before it's all said and done, but for now, it's a low budget build.  I have removed the rear frame section as well and will try to cut down the stock seat to an appropriate look.  I'm going to have to either fab a seat pan or see if I can source something that will work.  for a prototype, I chopped down the stock seat.  it looks good for a concept, but needs proper finishing to look right.

the coolant reservoir had already been relocated by the previous owner.  I plan to fab an inner fairing.  might be able to use the stock one with some modifications.  the battery area will be covered with an oval numbered disk for some "authenticity".

still thinking about the rear shock.  perhaps a ZZR1200 or an aftermarket progressive HD.  I mounted one of those on my sidecar rig and it's pretty stiff.  the 05 model has the ZZR on it.  since it's primarily for 2-up riding, I might replace it and move the ZZR to the cafe.

right now I need an ignition switch and gas cap with keys.  the previous owner said he would mail the key, but have tried several times to get him to send it to no avail.  could get a locksmith.  we'll see.

I also need a right footpeg and bracket.

if anyone has spare parts, holler at me.
Title: Re: Cafe Build of a C10
Post by: DC Concours on December 28, 2018, 10:33:22 AM
That already looks nice. How did you remove the rear wheel fender and how is the seat supported?
Title: Re: Cafe Build of a C10
Post by: sport rider on December 28, 2018, 02:11:08 PM
rear wheel fender is just a bunch of bolts here and there to remove it.  the rear frame section, which is bolt on, is removed too.  Right now the seat is just sitting on the frame that is left.  I'm thinking I'll use the bolt holes where the rear sub-frame connected to use quick connect pins to hold the seat on for a final solution.  I'm going to have to fabricate a hoop which will connect at the same spot as well.  that will support brake lights, turn signal and license plate.
Title: Re: Cafe Build of a C10
Post by: kzz1king on December 29, 2018, 08:46:37 AM
Looks like a fun project. Great platform to build on
Wayne
Title: Re: Cafe Build of a C10
Post by: sport rider on December 19, 2019, 10:15:52 AM
Old post resurrection.  I've basically just been tinkering with the bike, fixing odds and ends over this year.  I've got all the basics going and am down to the seat and support development.  I've bought some steel pipe to bend into a tail section.  from there I plan to figure out a tail section cover and then move back to creating the seat/pan/cover.  I'm hoping that I'll have some time to devote to it over the winter months.

attached pic is most recent of where things sit, but I did have to replace the tank, so paint is still a bit up in the air.  I'm actually thinking perhaps going with a medium blue color.  but I have some seat pan configuration ideas in my head, so hope to be able to make the progress.
Title: Re: Cafe Build of a C10
Post by: DC Concours on December 19, 2019, 04:59:42 PM
Good going on the project. I like the orange paint. Keep it.
Title: Re: Cafe Build of a C10
Post by: gpineau on December 19, 2019, 05:03:17 PM
Mine is cut off about the same place as yours but my seat is also cut at the same place.  For the license plate , tail light, and turn signals I made a bracket out of homedepot angle iron and steel pipe.

The side fairings I got for $38 including shipping. The guy said they would fit so I am going on faith.
I found another pair but the guy wants $50 for them.

https://www.ebay.com/itm/Concours-Side-covers-ZG1000-A8/301839573250?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3D01223620fc024750a29b99b578177d91%26pid%3D100675%26rk%3D2%26rkt%3D15%26sd%3D223688878261%26itm%3D301839573250%26pmt%3D0%26noa%3D1%26pg%3D2380057&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3A3531dbdc-22bb-11ea-bd15-74dbd180e886%7Cparentrq%3A2097982c16f0a860d2d3ab46ffb5ac4a%7Ciid%3A1 (https://www.ebay.com/itm/Concours-Side-covers-ZG1000-A8/301839573250?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3D01223620fc024750a29b99b578177d91%26pid%3D100675%26rk%3D2%26rkt%3D15%26sd%3D223688878261%26itm%3D301839573250%26pmt%3D0%26noa%3D1%26pg%3D2380057&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3A3531dbdc-22bb-11ea-bd15-74dbd180e886%7Cparentrq%3A2097982c16f0a860d2d3ab46ffb5ac4a%7Ciid%3A1)
Title: Re: Cafe Build of a C10
Post by: gpineau on December 19, 2019, 05:22:08 PM
Have you taken it for a ride yet? Do you have any problem with that wrapping around the tail pipes? Only one of my pipes had it and it smoked like crazy and gave off strange smelling vapors.  I ended up cutting it off.

Also I found an air box for mine so it looks more stock (ish)

I let mine sit for a long time but now I am getting anxious to get it finished. As spare time and money permits.
Title: Re: Cafe Build of a C10
Post by: MAN OF BLUES on December 19, 2019, 06:43:00 PM
the fabric wrap on the tubes, just holds moisture, and will eventually lead to spiral splits on the pipe, from migration where it's wrapped with the wire.

The pipes, being an alloy of Stainless, don't really need that... it' just something that cause another failed component, especially when you don't even have mufflers, keeping the heat in... :rotflmao:

Rock on man, I like the Orange paint...

oh, take a razor knife to those fork "gaitors" and cut them in half... the look like "rumple forskin"...  ::) 8)

you are on the way tho...
Title: Re: Cafe Build of a C10
Post by: sport rider on December 20, 2019, 10:08:58 AM
Have you taken it for a ride yet? Do you have any problem with that wrapping around the tail pipes? Only one of my pipes had it and it smoked like crazy and gave off strange smelling vapors.  I ended up cutting it off.

Also I found an air box for mine so it looks more stock (ish)

I let mine sit for a long time but now I am getting anxious to get it finished. As spare time and money permits.

no particular problem with the wrap except that I've gotten some coolant and oil spilled on them which smokes a bit when they get hot.  I'm likely going to remove it.  just something else to do.  :)

I'm probably going to go back to the air box.  I've got three sets of carbs and one of them will go off to Steve for a makeover.  it's time to get it running "right".
Title: Re: Cafe Build of a C10
Post by: sport rider on December 20, 2019, 10:12:05 AM
the fabric wrap on the tubes, just holds moisture, and will eventually lead to spiral splits on the pipe, from migration where it's wrapped with the wire.

The pipes, being an alloy of Stainless, don't really need that... it' just something that cause another failed component, especially when you don't even have mufflers, keeping the heat in... :rotflmao:

Rock on man, I like the Orange paint...

oh, take a razor knife to those fork "gaitors" and cut them in half... the look like "rumple forskin"...  ::) 8)

you are on the way tho...

Wrap will come off at some point.  just bigger fish to fry at the moment.  the big problem with the fork protectors is they are old and rotted.  they are going to get replaced.  Perhaps pink.  :)


oh...and muffler is nicely placed on the other side of the bike.  doesn't it look cool having this side more "naked"?   :thumbs:
Title: Re: Cafe Build of a C10
Post by: gPink on December 20, 2019, 03:24:58 PM
pink is good  :)
Title: Re: Cafe Build of a C10
Post by: MAN OF BLUES on December 20, 2019, 03:44:57 PM
Wrap will come off at some point.  just bigger fish to fry at the moment.  the big problem with the fork protectors is they are old and rotted.  they are going to get replaced.  Perhaps pink.  :)


oh...and muffler is nicely placed on the other side of the bike.  doesn't it look cool having this side more "naked"?   :thumbs:

groovy.... need pics of all the sides, I like it...  :thumbs: :thumbs: :thumbs:
what exhaust did you use, to be lefty mounted??  I have a set (new, un used) Ontario pipes, but they are right hand side....

Oh, and I give thumbs up on the Pink, fork gaitors.... (actually had a red set, that bleached out to Pink, on my '74 KX450 MX bike... took a lot of chides from my pals when I was racing...  but none of them ever "saw" the front of that bike... jut the clods of "mud grenades" I launched at them thru each moto...) :rotflmao: :rotflmao: :rotflmao: :hitfan: :stirpot: :hail: :hail: :rotflmao:
Title: Re: Cafe Build of a C10
Post by: gpineau on December 21, 2019, 04:29:23 PM
I like that you were able to move you pipes to the other side. I bought a couple stock mufflers just because it was so loud.  I been working on mine today, cleaning up the loose wires and hoses. Stole the mirrors off my magna. The look better than those sticking our the ends of the handle bars.

 I was standing back looking it over and it just didn't look "right" to me.  I put the tank and the seat on it and had another look and it still looks funny. That huge tank and tiny seat make it look like a dwarf with a hunch back.

  I am thinking of extending the frame back to at least the middle of the back wheel. What do you think?
Title: Re: Cafe Build of a C10
Post by: sport rider on December 22, 2019, 09:40:49 AM
I understand everything you are saying.  the single side tube can be homemade with an extra set of pipes, some cutting and welding.  it's a home-made deal as there's no aftermarket that does it.  Per others, this does NOT improve performance (and might even lessen it), but there's plenty of power for my needs and mine is as much an effort of looks.  (same approach for the pods i'm working with). 

you might try to find some aftermarket mufflers which are upswept rather than the stock ones.  I had an aftermarket can which I attached to the frame using one of the connection holes on the frame.  (can provide a pic if you want).  I bought it online to specific size and had a local muffler shop bend it to the angle which matched what I had the muffler set to.  it could be easily done on both sides to make a dual upswept exhaust.  I think that would look good if you got the right angle set.

as for the seat, I year you and am struggling with design on that part too.  I found out a few things.  first, I believe the frame tubing is slightly over 7/8 inches internal diameter.  I'm able to use one of the handlebar ends to slide inside it.  I am planning to cut the 7/8 ends off the stock bars and use that as a "slug" to slide into the frame tube and weld in place.  I've sourced some pipe which is 7/8 ID and 1 1/8 OD.  I plan to bend this into a loop for the back end which will align with the frame width.  then the 7/8 handlebar tube will slide into that and weld together.

once that part is done, I plan to fabricate a large hump on the back of the loop.  making it sufficiently large so as to match the look of the large tank.  hopefully that will balance it out a bit.  it's all about the look, so will see.  I'm including here a pic of a "model" I'm going off of.  I think it looks reasonable.  I know the guy which did this did a fiberglass build.  Once all that is done, I plan (I think) to use a cut down version of the stock seat pan and build up foam to match the angles I have in mind.  This can be custom covered.  I just need to work out a plan to attach the seat pan, using the front slide-in and fabricating a simple clip system for the back end of it.

once all that is done, I'll fabricate some simple mounting plates for the rear brake light, signals, and license bracket.  the guy who built the one in the pic used the original brake light and fabbed the rear hump around it.
Title: Re: Cafe Build of a C10
Post by: gpineau on December 22, 2019, 11:11:43 AM
I like that look. It looks more balanced. And the seat looks more like a motorcycle seat. Mine looks like a bicycle seat.   The foam in the seat has been trimmed down. That makes it low enough I can hold it upright without tipping over. But still I need to stand on the balls of my feet.  I have a lowering kit still in a box that I was going to use on my other Connie but if in the end, if I like this bike better I will use the lowering links on this bike and sell the other. 

Just for fun I ordered a Cafe Racer seat from China just to see how it would look. It was only $30 son no big loss if I throw it away.
 
My tag, tail lights and turn signals are attached to an angle iron and that is welded to two pieces of pipe that slide into the back of the frame like a trombone. I have about 9 inches that I can experiment with.  To hold it in place I use the same bolts that hold the seat down. 

But seriously it looks weird. I know I am going to rework the tail end but I don't want to start anything until the side covers I ordered arrive. I liked the photo that MOB posted a few days ago. Naked but not completely. I liked that color too.

For mufflers I'm going to stick with what I got until I am convinced the bike is going to be a keeper.  Its been a depressing year but I am starting to enjoy this again.

Keep posting so I can copy what you're doing.. :thumbs:
Title: Re: Cafe Build of a C10
Post by: sport rider on December 23, 2019, 07:32:26 AM
here's a couple of how I framed in the back end.
Title: Re: Cafe Build of a C10
Post by: sport rider on December 23, 2019, 07:51:22 AM
Here's the results of my progress yesterday.  I asked a friend of mine to help me bend some tube to make the rounded back end so I could start thinking about the hump design.  he shot me an address and said he was heading that way to turn the heat on.  When I arrived, he was there but also a surprise guest.  The shop he told me to meet him at belongs to Ron Hornaday Jr.  Yep...the NASCAR Ron Hornaday Jr.  I was surprised to put it mildly.   Ron took a break from a racing frame that he was putting together and we all pretty much tore into my bike.  Ideas were flowing and at the end of the day, the picture is the result.  We were actually there for about 8 hours.  I keep pinching myself that I had all this great help!

Ron had some cheap rattle can paint sitting around his shop.  So we put a quick coat of black on the frame parts and he decided the gold on the rear cowl would match the tank.  well....almost.  :D

BTW....his shop?  about a 40 x 60 building.  early 70s dodge charger was up on a lift under a tarp.  below that was a modded frame from a Chevy Luv.  Beside that was a dirt late model track car up on a lift as well.  Then there was the body of the Chevy Luv that he's working on.  Next to that was his frame station which had an almost complete racing frame on it.  To the left coming around the shop were two other dirt track cars under covers.  one he was rebuilding for another driver, and one which is his son-in-law's who races regularly (it's off season, of course).

there's still a bit to do, but we've got everything roughed in.  Ron said to bring it back when I get closer to the finished product and we'd make some better parts, particularly the fender protection underneath.

#cloudnine

 :banana
Title: Re: Cafe Build of a C10
Post by: connie_rider on December 23, 2019, 08:40:39 AM
Info on headers; I used these for about 3 years before giving them to Dave for his build.
Head pipes were Frankensteined from a set of Suzuki aftermarket headers and are made of SS.
 Head pipes are too big, so {in an attempt to gain low end} I machined SS anti-reversion venturi's for each head pipe.

The reason the pipes are wrapped is to cover the "Frankensteining", and because the tubing is very thin and big.
   Radiates a lot of heat, and is extremely close to fan and lower water lines.
    {The wrap was an attempt to reduce heat in those area's a bit}

No HP loss; Bike produced 94 peak HP on my dyno after the install. {2 HP over stock}
     Not much HP gain, but it had a nice smooth plot.
      As you might imagine, it lost some low end torque..

Muffler is a modified Kerker.
    Changed mounts and name tag to convert it from right side to left, and installed diverters inside to quieten it a bit.
    Was installed on the left vs right as I felt that it looked better on the left {and I wanted to be different}.
     NOTE: Dave moved the muffler up to this location for looks on this bike.
                Was in stock location when I had it. I like his idea.

Ride safe, Ted
Title: Re: Cafe Build of a C10
Post by: gpineau on December 23, 2019, 09:08:46 AM
What? "my dyno"!....You got a dyno? I'm jealous now. Let me see, ok?   I want one.

Title: Re: Cafe Build of a C10
Post by: connie_rider on December 23, 2019, 10:14:29 AM
I bought it at an auction, and later sold it.
Steve Sefsick now owns it, and {by working with Dynojet} has greatly improved it.

Ride safe, Ted
Title: Re: Cafe Build of a C10
Post by: MAN OF BLUES on December 23, 2019, 12:57:07 PM
WOOOOOHOOOOOOO...
That's soooo cool....
I think I know where that gold paint came from.... you gonna have him sign his number on that tail section???

(https://cdn3.volusion.com/xdfjn.bvnsv/v/vspfiles/photos/T16P249725241-2.jpg?v-cache=1567158648)
Title: Re: Cafe Build of a C10
Post by: sport rider on December 23, 2019, 01:35:07 PM
I hadn't thought of that.  maybe after paint I'll have him autograph the back and clear it.  This one went from a project build to a sentimental keepsake. :)
Title: Re: Cafe Build of a C10
Post by: MAN OF BLUES on December 23, 2019, 03:33:16 PM
SERIOUSLY SO..... :thumbs: :thumbs: :thumbs: :thumbs: :hail: :banana :banana
Title: Re: Cafe Build of a C10
Post by: sport rider on December 30, 2019, 11:47:41 AM
what do you think of the color?  :)
Title: Re: Cafe Build of a C10
Post by: gpineau on December 30, 2019, 12:17:58 PM
I really like it. Good choice, Nice and bright. 

Looks ready to ride.

Mine is still hiding in the garage and has not seen sunshine in a long time.

OOPs! I take that back. I just noticed the carbs are missing. But you got the airbox installed. I think it looks much better with an airbox.
Title: Re: Cafe Build of a C10
Post by: sport rider on December 30, 2019, 03:35:22 PM
I happened to have a can of duplicolor to match the 05 color of the tank, so I sprayed the front and back to match.  this isn't the final color, but will be fine to get it running and rolling.  paint can come later. 

yeah, carbs are off.  waiting to hear from Steve to get them sent to him for cleaning.  I got the turn signals for the back.  still have the brake light to install. just license plate bracket, mirrors, and decent tires to get it on the road.
Title: Re: Cafe Build of a C10
Post by: gpineau on December 30, 2019, 04:25:11 PM
My brake light, license plate bracket was all in one. If you haven't already bought one have a look.

https://www.amazon.com/gp/product/B06XW5P3HB/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 (https://www.amazon.com/gp/product/B06XW5P3HB/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1)

Your getting close....

I am postponing adding any length to the frame until I know what the seat is going to be. I am waiting for that cafe- seat to arrive from china to see if I am going to use it or not. 

Got it started again today. It's been really rough starting in the cold weather.  I've got a new problem with backfiring on the right side. Wasn't doing that last time I started it.
I think you are going to be on the road long before me.
Title: Re: Cafe Build of a C10
Post by: Rubber_Snake on December 30, 2019, 09:23:39 PM
It’s looking great.  That seam at the bottom of the gas tank bugs me, though.  It reminds me that there used to be bodywork on the bike.  I wonder if it were painted black, if that would hide it better?  You could test fit with electrical tape to get a visual before painting.  Just a thought.  Keep up the good work!
Title: Re: Cafe Build of a C10
Post by: sport rider on December 31, 2019, 11:53:51 AM
My brake light, license plate bracket was all in one. If you haven't already bought one have a look.

https://www.amazon.com/gp/product/B06XW5P3HB/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 (https://www.amazon.com/gp/product/B06XW5P3HB/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1)

Your getting close....

I am postponing adding any length to the frame until I know what the seat is going to be. I am waiting for that cafe- seat to arrive from china to see if I am going to use it or not. 

Got it started again today. It's been really rough starting in the cold weather.  I've got a new problem with backfiring on the right side. Wasn't doing that last time I started it.
I think you are going to be on the road long before me.

I ordered this for the brake light.
https://www.ebay.com/itm/4-Cafe-Racer-Flush-Mount-LED-Stop-Brake-Tail-Light-Smoked-Lens-SAE-DOT/183720182349?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649 (https://www.ebay.com/itm/4-Cafe-Racer-Flush-Mount-LED-Stop-Brake-Tail-Light-Smoked-Lens-SAE-DOT/183720182349?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649)

plan to put it along the line of the rear frame on the back.  I also got some license plate bolts that are LED lighted for the plate light.  That and a very little bit of bracket fabrication should get me finished with the rear end.
Title: Re: Cafe Build of a C10
Post by: sport rider on December 31, 2019, 11:55:53 AM
It’s looking great.  That seam at the bottom of the gas tank bugs me, though.  It reminds me that there used to be bodywork on the bike.  I wonder if it were painted black, if that would hide it better?  You could test fit with electrical tape to get a visual before painting.  Just a thought.  Keep up the good work!

I've seen some old tanks like this which they have heated up the metal and worked it under.  I do like that look.  When I decide to get finish work done, I'll consider that too.  :)
Title: Re: Cafe Build of a C10
Post by: gpineau on December 31, 2019, 12:25:16 PM
On my other C10 I used a rubberized door trim to define the lines around the tank and the cowlings.  Have a look. It might smooth out the transition line around the tank.
https://www.amazon.com/gp/product/B01BWKCUAO/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 (https://www.amazon.com/gp/product/B01BWKCUAO/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1)
Title: Re: Cafe Build of a C10
Post by: sport rider on January 01, 2020, 01:41:42 PM
that might be a cheap way to hide it.  maybe I'll try it out with some of the fairing edge cover that runs down along the side.  I have some laying around from the disassembly.  thx!
Title: Re: Cafe Build of a C10
Post by: Boomer on January 02, 2020, 07:04:39 AM
Be wary of using that edge strip stuff as it holds water and will quick-rot your tank for you.
I like the idea of "hiding" the edge by painting it black though.  ;D
Title: Re: Cafe Build of a C10
Post by: sport rider on January 13, 2020, 08:33:39 AM
got a few more parts and made some progress over the weekend.  Tail light, brake light and turn signals all working as expected.

now if that slacker Steve Sefsick would get my carbs back to me, I can make an actual test run.   :rotflmao:
Title: Re: Cafe Build of a C10
Post by: MAN OF BLUES on January 13, 2020, 03:54:13 PM
got a few more parts and made some progress over the weekend.  Tail light, brake light and turn signals all working as expected.

now if that slacker Steve Sefsick would get my carbs back to me, I can make an actual test run.   :rotflmao:

cut Steve some slack, seriously... he just got out of the hospital after having some serious heart problems...

now, if that was said in a humorous form, after recently talking to him, and him saying check your mail tomorrow.. it's ok...
Title: Re: Cafe Build of a C10
Post by: sport rider on January 14, 2020, 11:26:58 AM
cut Steve some slack, seriously... he just got out of the hospital after having some serious heart problems...

now, if that was said in a humorous form, after recently talking to him, and him saying check your mail tomorrow.. it's ok...

yeah.  I talked with him.  knew he was seriously sick and told him this is NOT a priority before getting himself better.  Just giving him a hard time should he happen upon my post.

He did tell me he'd probably get to it in a couple weeks.
Title: Re: Cafe Build of a C10
Post by: sport rider on February 01, 2020, 12:56:02 PM
Still waiting for my carbs to get back from Steve, but in the mean time, I made some more progress.....

Two of these things ard not like the others.  :)
Title: Re: Cafe Build of a C10
Post by: sport rider on February 01, 2020, 12:58:06 PM
closer up....
Title: Re: Cafe Build of a C10
Post by: sport rider on February 01, 2020, 12:59:09 PM
...and another closeup.

Title: Re: Cafe Build of a C10
Post by: connie_rider on February 02, 2020, 09:28:40 AM
I really hate to say this,,, but, ya dun good..
  {Please don't tell anyone I sed that}

I think the rear of the bike {above the tail light} needs either a sticker {with a neat saying}, or a light of some kind.

I found something that serves both thoughts, and "perfectly" expresses your "shining" personality..   :thumbs: :thumbs:

https://www.ebay.com/itm/Motorcycle-Tail-Rear-Lamps-Middle-Finger-Signs-Taillights-For-HARLEY-HONDA-KTM/252053819789?_trkparms=aid%3D555018%26algo%3DPL.SIM%26ao%3D1%26asc%3D20131003132420%26meid%3Dfbab95f66c7f443788bc41d6f1649c7d%26pid%3D100005%26rk%3D5%26rkt%3D12%26mehot%3Dco%26sd%3D282424533028%26itm%3D252053819789%26pmt%3D1%26noa%3D0%26pg%3D2047675&_trksid=p2047675.c100005.m1851 (https://www.ebay.com/itm/Motorcycle-Tail-Rear-Lamps-Middle-Finger-Signs-Taillights-For-HARLEY-HONDA-KTM/252053819789?_trkparms=aid%3D555018%26algo%3DPL.SIM%26ao%3D1%26asc%3D20131003132420%26meid%3Dfbab95f66c7f443788bc41d6f1649c7d%26pid%3D100005%26rk%3D5%26rkt%3D12%26mehot%3Dco%26sd%3D282424533028%26itm%3D252053819789%26pmt%3D1%26noa%3D0%26pg%3D2047675&_trksid=p2047675.c100005.m1851)

Ride safe, Ted  :feedback:
Title: Re: Cafe Build of a C10
Post by: sport rider on February 02, 2020, 10:40:17 AM
I really hate to say this,,, but, ya dun good..
  {Please don't tell anyone I sed that}

I think the rear of the bike {above the tail light} needs either a sticker {with a neat saying}, or a light of some kind.

I found something that serves both thoughts, and "perfectly" expresses your "shining" personality..   :thumbs: :thumbs:

https://www.ebay.com/itm/Motorcycle-Tail-Rear-Lamps-Middle-Finger-Signs-Taillights-For-HARLEY-HONDA-KTM/252053819789?_trkparms=aid%3D555018%26algo%3DPL.SIM%26ao%3D1%26asc%3D20131003132420%26meid%3Dfbab95f66c7f443788bc41d6f1649c7d%26pid%3D100005%26rk%3D5%26rkt%3D12%26mehot%3Dco%26sd%3D282424533028%26itm%3D252053819789%26pmt%3D1%26noa%3D0%26pg%3D2047675&_trksid=p2047675.c100005.m1851 (https://www.ebay.com/itm/Motorcycle-Tail-Rear-Lamps-Middle-Finger-Signs-Taillights-For-HARLEY-HONDA-KTM/252053819789?_trkparms=aid%3D555018%26algo%3DPL.SIM%26ao%3D1%26asc%3D20131003132420%26meid%3Dfbab95f66c7f443788bc41d6f1649c7d%26pid%3D100005%26rk%3D5%26rkt%3D12%26mehot%3Dco%26sd%3D282424533028%26itm%3D252053819789%26pmt%3D1%26noa%3D0%26pg%3D2047675&_trksid=p2047675.c100005.m1851)

Ride safe, Ted  :feedback:

You are now on Denise's list.   :battle:
Title: Re: Cafe Build of a C10
Post by: connie_rider on February 02, 2020, 11:00:13 AM
That's ok.
   I think I was permanently on Denise's list anyway. <evil grin>  :o

Ride safe, Ted
Title: Re: Cafe Build of a C10
Post by: sport rider on February 13, 2020, 03:10:43 PM
got word that Steve is back among the living and has my carbs in progress.  in the mean time, I made HUGE progress this week with the addition below.  Those new horns really HONK!

Sweet aren't they....I know you wanna say so.

Title: Re: Cafe Build of a C10
Post by: gpineau on February 13, 2020, 07:17:21 PM
We seem to be following the same path. Mine looks just like yours.  I got mine from Amazon and they are loud. I bet I used the same bolts on the front to hold them on.
https://www.amazon.com/gp/product/B01C8F0AUY/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 (https://www.amazon.com/gp/product/B01C8F0AUY/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1)

Looking forward to you getting your carbs back.

Title: Re: Cafe Build of a C10
Post by: Rubber_Snake on February 14, 2020, 08:49:45 AM
got word that Steve is back among the living and has my carbs in progress.  in the mean time, I made HUGE progress this week with the addition below.  Those new horns really HONK!

Sweet aren't they....I know you wanna say so.

Glad to hear about Steve. 

Quick question, did either of you have to install a relay for these horns?  I’d like to get something louder for my C14.

Ray
Title: Re: Cafe Build of a C10
Post by: gpineau on February 14, 2020, 09:21:39 AM


Quick question, did either of you have to install a relay for these horns?  I’d like to get something louder for my C14.

Ray
I didn't add a relay. I just connected to the existing horn wires.
Title: Re: Cafe Build of a C10
Post by: sport rider on February 14, 2020, 12:25:20 PM
We seem to be following the same path. Mine looks just like yours.  I got mine from Amazon and they are loud. I bet I used the same bolts on the front to hold them on.
https://www.amazon.com/gp/product/B01C8F0AUY/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 (https://www.amazon.com/gp/product/B01C8F0AUY/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1)

Looking forward to you getting your carbs back.

No...mine were only 11 bucks on ebay.  Saved that extra 3 dollars for gas.   :banana
Title: Re: Cafe Build of a C10
Post by: sport rider on February 14, 2020, 12:26:58 PM
Glad to hear about Steve. 

Quick question, did either of you have to install a relay for these horns?  I’d like to get something louder for my C14.

Ray

mine were just plug and play as well.  Nicole from the COG club was doing a set of horns for C14s.  You might want to look into getting her honkers.  ;)
Title: Re: Cafe Build of a C10
Post by: sport rider on February 24, 2020, 09:00:32 AM
I got my carbs back from Steve late last week.  Spent some time Saturday installing them and getting all the cables and such working as expected.  Good news is she started right up and worked just as expected.  Bad news is the clutch was slipping terribly.  I got some new oil and put in.  it was better, but still slipping under harder acceleration.  I had already replaced the clutch pads last summer when getting some of the internals working.  I don't recall that I replace the springs at the same time.  I have them ordered and will pull the side case off to fix it.  If it's not one thing, it's another.

The good news is other than the slipping clutch, everything else was working fine.  once I get this solved and get some good tires on it, she'll be road-ready.
Title: Re: Cafe Build of a C10
Post by: connie_rider on February 24, 2020, 05:16:55 PM
Did you go thru the clutch slave cylinder?
Corrosion can build up in it and prevent the clutch from fully engaging.

Ride safe, Ted
Title: Re: Cafe Build of a C10
Post by: sport rider on February 25, 2020, 09:48:12 AM
Did you go thru the clutch slave cylinder?
Corrosion can build up in it and prevent the clutch from fully engaging.

Ride safe, Ted

Slave cylinder was replaced as part of the motor refresh.  the old one was frozen solid.  if it comes down to it, I'll pull the one from Kurt's bike and retry, but for now we'll give this a try.
Title: Re: Cafe Build of a C10
Post by: sport rider on March 02, 2020, 12:22:48 PM
I got all the clutch parts in late last week and spent a short bit Friday night getting everything back together.  I was still having clutch slippage, so I swapped both the master and slave from the parts bike to this one.  it's working now, but I think I still have more bleeding to do because the engagement point for the clutch is very close to the grip and I'm having a bit of trouble getting it to slide into neutral.

I ran into a charging issue when I took it out for it's initial shakedown run.  after pulling a few things off, I found a broken wire from the alternator.  once I repaired that, it did fine.  then took it out for another run, including stopping for some fuel.  started back up with no problems.  my horns and turn signals (front) have stopped working.  going to have to do a bit more fiddling with the wiring up there.

I've got new tires on the way.  I am going to pull a few parts off the parts bike including a rear shock and clutch line (braided).  more tinkering and fixing on the way, but it's pretty close to getting the inspection done.

The test rides were a blast.  the exhaust note both growls and screams at various RPMs.  I will definitely be getting a ticket on this bike at some point.  it's got worn out tires on it, so handling was sketchy.  with the better rear shock and some fresh shoes, that should be a great improvement.  under really hard acceleration, I was sliding back on the seat and had to hold on to the grips hard.  then I realized I could just slide my butt back against the cowl, lean in a bit, and ride her the way she wanted to be ridden.

this is going to be a fun spring!!!
Title: Re: Cafe Build of a C10
Post by: gpineau on March 02, 2020, 06:03:34 PM
Sounds like you getting closer.    It takes patience to put someone's old wreck back together. Like a game of wack a mole..It's one thing after another until all the gremlins have given up..

I know the feeling when its running right.

I'm getting closer I may catch you if I don't run out of $.
Title: Re: Cafe Build of a C10
Post by: sport rider on March 03, 2020, 08:48:29 AM
Christmas!
Title: Re: Cafe Build of a C10
Post by: sport rider on March 04, 2020, 11:23:13 AM
a little cleaning up and fixing up before tire goes on....
Title: Re: Cafe Build of a C10
Post by: sport rider on March 09, 2020, 09:13:28 AM
so, I got the clutch put back together and had to also swap out the master and slave cylinders from my parts bike.  after a couple rounds of bleeding the lines, it seems to be working well.  I also got the tires on after the above prettying up of the rims.  I also grabbed the progressive shock off the parts bike and put it on the project bike as well.

I also had to replace the turn signals because I blew out both bulbs and since they were not LED, I decided to get another set.

With all the done, I got a chance to take it out for a good ride this weekend.  A friend of mine is just learning to ride.  he was anxious to get out and get some practice, so I took the project bike out for a slow-paced ride with him.  we were out a couple hours and did about 50 to 60 miles.  other than a wiring problem with the horns, it ran fine and didn't have any problems at all.

Very happy with the progress so far and once I get the horns sorted out, it will be ready for inspection and licensing.

yea!!!
Title: Re: Cafe Build of a C10
Post by: connie_rider on March 10, 2020, 08:09:59 AM
Sounds good. Anxious to hear it roar.
Any recent picture's of the assembled bike?

Ride safe, Ted
Title: Re: Cafe Build of a C10
Post by: gpineau on March 10, 2020, 05:37:49 PM
good job, Soon to be legal and racing from cafe to cafe.
Title: Re: Cafe Build of a C10
Post by: sport rider on March 11, 2020, 08:42:43 AM
my headlight stopped working.    :yikes:  :censored:
Title: Re: Cafe Build of a C10
Post by: connie_rider on March 11, 2020, 09:44:46 AM
Arghhh!!
Prolly a short or broken wire..

Ride safe, Ted
Title: Re: Cafe Build of a C10
Post by: sport rider on March 11, 2020, 11:11:22 AM
gonna start at the headlight relay and work out from there.  I was hoping to ride it to work today.  it foiled my plans.  :(
Title: Re: Cafe Build of a C10
Post by: MAN OF BLUES on March 11, 2020, 07:16:51 PM
didja try smacking the J box a couple times, with the bike running?

just try it once, before tearing into "wires".... might be a faulty relay... if so, a quick resolder will fix it..
Title: Re: Cafe Build of a C10
Post by: sport rider on March 12, 2020, 09:33:53 AM
didja try smacking the J box a couple times, with the bike running?

just try it once, before tearing into "wires".... might be a faulty relay... if so, a quick resolder will fix it..

first thing I will probably do is swap the jbox from one of the other bikes to test it.  :)
Title: Re: Cafe Build of a C10
Post by: Hooligan on March 13, 2020, 03:07:58 AM
Good luck, I hope you get the issues resolved soon. :thumbs:
Title: Re: Cafe Build of a C10
Post by: sport rider on March 13, 2020, 07:26:26 AM
all good.  note to self....check high beam when testing and also put on glasses when looking at the bulb to see if it's burned out.  low beam was out.  geez....
Title: Re: Cafe Build of a C10
Post by: VirginiaJim on March 14, 2020, 04:27:45 AM
I find glasses work quite well with them either on your head or filled with beer.
Title: Re: Cafe Build of a C10
Post by: sport rider on March 16, 2020, 02:06:00 PM
headlight fixed. replacement horn hooked up and both are honking like goosed geese.  ready to have it inspected and get it on the road.  weather sucks.   :banghead: :banghead: :banghead: :thumbdown :thumbdown :thumbdown
Title: Re: Cafe Build of a C10
Post by: connie_rider on March 17, 2020, 11:02:16 AM
err/repeat; Any recent picture's of the assembled bike?

Ride safe, Ted
Title: Re: Cafe Build of a C10
Post by: sport rider on March 26, 2020, 03:44:10 PM
since enough is never enough, I've made a new acquisition.  fat.....skinny.....
Title: Re: Cafe Build of a C10
Post by: sport rider on March 26, 2020, 05:08:55 PM
the new look....
Title: Re: Cafe Build of a C10
Post by: gPink on March 26, 2020, 05:41:33 PM
like it!  :thumbs:
Title: Re: Cafe Build of a C10
Post by: tweeter55 on March 26, 2020, 06:20:41 PM
+1!
Title: Re: Cafe Build of a C10
Post by: sport rider on April 03, 2020, 06:49:27 AM
I got a zx900r seat to fit up to the tank.  I ended up cutting it and the C10 seatpan up and grafting them together.  the zr seat was not flat like the C10, so did not look right back toward the rear cowl.  fits up nicely to the tank now.

I also got some 43mm clipons and installed them.  (43mm because those are ZRX1100 forks, not stock C10).  I like the look better.  I also have some clubman bars on order.  I will try them as well and decide which I like better.

lastly, I got a C10 left footpeg and mounted it to the C10 bracket.  it effectively gave me a 1up-1back rearset.  Hopefully the ergos will be better.
Title: Re: Cafe Build of a C10
Post by: j_wahl91 on April 03, 2020, 07:16:09 AM
That looks real solid, well done! Side note: did you get your key from the guy? If not, you can get the code for a key cut from the bottom of the ignition assembly. Figured I'd share in case you weren't aware of that.
Title: Re: Cafe Build of a C10
Post by: sport rider on April 03, 2020, 08:31:10 AM
didn't get a key, but I've since swapped out the ignition and tank cap for a parts bike I bought.  Had a local locksmith make a copy of that so have two available.  :)
Title: Re: Cafe Build of a C10
Post by: sport rider on April 13, 2020, 08:53:38 AM
Here's semi-final recap of the bike.  it's as far as I want to take it for now.  going to take some time to ride and enjoy it.

1998 Kawasaki Concours. front end is from a 1999 ZRX1100. clip on bars, mirrors, headlight and speedo are aftermarket. Tank is from a 1985 ZX900R. Rear wheel is from a 2002 Kawasaki Meanstreak. rear brake rotor from Nomad 1500. Footpegs are from a Concours 14. Seat is a ZX900r grafted to the stock 98 Concours seat pan with a custom cover. Rear end and cowl are custom built. exhaust is a custom 4-2-1.
Title: Re: Cafe Build of a C10
Post by: MAN OF BLUES on April 13, 2020, 10:50:35 AM
Here's semi-final recap of the bike.  it's as far as I want to take it for now.  going to take some time to ride and enjoy it.

1998 Kawasaki Concours. front end is from a 1999 ZRX1100. clip on bars, mirrors, headlight and speedo are aftermarket. Tank is from a 1985 ZX900R. Rear wheel is from a 2002 Kawasaki Meanstreak. rear brake rotor from Nomad 1500. Footpegs are from a Concours 14. Seat is a ZX900r grafted to the stock 98 Concours seat pan with a custom cover. Rear end and cowl are custom built. exhaust is a custom 4-2-1.

Nice job man...
I suggest a quick safety mod tho,, as I've chewed thru hoses from having them contact the fairing plastic even...
take a 4" long piece of 1/4" rubber hose, slit it lengthwise, and slip it in place on that sharp front edge seam on the tank, where the radiator hose is rubbing...

ride safe, and enjoy it for a while
Title: Re: Cafe Build of a C10
Post by: sport rider on April 13, 2020, 12:22:26 PM
Nice job man...
I suggest a quick safety mod tho,, as I've chewed thru hoses from having them contact the fairing plastic even...
take a 4" long piece of 1/4" rubber hose, slit it lengthwise, and slip it in place on that sharp front edge seam on the tank, where the radiator hose is rubbing...

ride safe, and enjoy it for a while

thanks for saving me from myself!  I just went and took a look.  there is about 1/4 inch clearance on the C10 tank, but the ZX900R tank is actually pressing on the hose.  I'll fix this right away!
Title: Re: Cafe Build of a C10
Post by: kkja13 on April 13, 2020, 12:40:54 PM
Looks great Sports Rider, I really like the tank!
Title: Re: Cafe Build of a C10
Post by: gpineau on April 13, 2020, 07:29:30 PM
Looks great. Ready to ride?

I'm ready but we are still under stay at home orders. Plus its snowing outside.

Title: Re: Cafe Build of a C10
Post by: sport rider on April 13, 2020, 07:49:26 PM
no snow here.  hoping to get out and ride a bit sometime this week or over the weekend.  poor bikes are sitting in the garage covered in pollen.   :'(
Title: Re: Cafe Build of a C10
Post by: connie_rider on April 14, 2020, 08:33:12 AM
I want a recording of a ride by, so we can hear it roar.

Ride safe, Ted
Title: Re: Cafe Build of a C10
Post by: gpineau on May 03, 2020, 12:25:34 PM
Do you have the stock handle bars on your bike?
The bars on mine have been change to straight and level with the forks. I'm sure the previous owner did that to make you lean down behind the wind shield in a true racer position.

But it is a real pain to ride.  I have to lean forward to reach them and  it is very uncomfortable.  I cant ride for more that 30 minutes then my back gives out.   
Title: Re: Cafe Build of a C10
Post by: sport rider on May 04, 2020, 08:19:15 AM
Do you have the stock handle bars on your bike?
The bars on mine have been change to straight and level with the forks. I'm sure the previous owner did that to make you lean down behind the wind shield in a true racer position.

But it is a real pain to ride.  I have to lean forward to reach them and  it is very uncomfortable.  I cant ride for more that 30 minutes then my back gives out.

are you looking for stock C10 bars?  I think I have some and may have risers too.
Title: Re: Cafe Build of a C10
Post by: gpineau on May 04, 2020, 10:47:07 AM
are you looking for stock C10 bars?  I think I have some and may have risers too.

OOPS !. I should have asked here first but I just bought some off ebay. Came to $48.00.
I thought about swapping out with my other C10 but then it would be uncomfortable to ride. 

Actually I am thinking of selling my other C10 and keeping this one. Since I lowered it, it is a little easier for me to handle. I can actually do a U-turn without stopping with this one. The  other one I have to tiptoe and walk it through a U-turn. Maybe if I lowered it too then I would have two keepers.  I have 4 bikes sitting here and my wife is wanting me to downsize. It's hard to decide what to keep.
 
If you have risers can you post a photo?

Title: Re: Cafe Build of a C10
Post by: gPink on May 04, 2020, 03:53:40 PM
OOPS !. I should have asked here first but I just bought some off ebay. Came to $48.00.
I thought about swapping out with my other C10 but then it would be uncomfortable to ride. 

Actually I am thinking of selling my other C10 and keeping this one. Since I lowered it, it is a little easier for me to handle. I can actually do a U-turn without stopping with this one. The  other one I have to tiptoe and walk it through a U-turn. Maybe if I lowered it too then I would have two keepers.  I have 4 bikes sitting here and my wife is wanting me to downsize. It's hard to decide what to keep.
 
If you have risers can you post a photo?

Are you deciding between the bikes or the wife?   :)
Title: Re: Cafe Build of a C10
Post by: sport rider on May 07, 2020, 01:54:49 PM
OOPS !. I should have asked here first but I just bought some off ebay. Came to $48.00.
I thought about swapping out with my other C10 but then it would be uncomfortable to ride. 

Actually I am thinking of selling my other C10 and keeping this one. Since I lowered it, it is a little easier for me to handle. I can actually do a U-turn without stopping with this one. The  other one I have to tiptoe and walk it through a U-turn. Maybe if I lowered it too then I would have two keepers.  I have 4 bikes sitting here and my wife is wanting me to downsize. It's hard to decide what to keep.
 
If you have risers can you post a photo?

sorry...no risers.  must have already given them to someone.  :(