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Old Streetfighter Motorcycle Forum Post 02-25-2011, 11:20 PM   #11
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

As the temp has again dropped, and 9" of snow piled up, I was forced back inside to continue planning. And spending money buying parts. As the gas prices keep rising, I'll need this project completed at the first sign of spring. R1 subframe, seats, and integrated led tail light are ordered. I'd like to pick up an exhaust kit, but may have to settle for what's on it now. Next up to order is tires. After that I may need a few small miscellaneous items, but mostly I need some good wrench time. Updates coming soon, as is the weather.

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Old Streetfighter Motorcycle Forum Post 02-27-2011, 06:54 PM   #12
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

Spent about an hour today taking more shit off. The bike probably lost 300 pounds with everything gone. Coolant is drained, radiator is off, exhaust is off, and subframe is gonzo. I'm half tempted to throw a seat pan on and give er hell. Next steps are to replace the cracked oil pan, replace the damaged side cover, and fabricate a right side driver peg. That thing is like the holy grail of eBay. Pictures will be uploaded when I get back to my laptop.

Pictures. Don't mind the messy garage, it'll clear out when the nice weather furniture get pulled out.






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Old Streetfighter Motorcycle Forum Post 03-03-2011, 10:37 PM   #13
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

I guess if I claim to have removed the radiator and exhaust, I should post the right pictures that show them off the bike.



Keep in mind that this bike is on the kick stand, but I'm wondering if the frame may be bent. I hope not. The right side took the majority of the damage, but aside from the initial laydown, it's all skid damage.I think my right handle bar may be bent too.



Also, more parts arrived today. These babies were waiting for me on my door step when I got home.



2005 R1 subframe and seats. It's considerably longer than I had anticipated. Oh well, guess I'll just have to make some more sparks.

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Old Streetfighter Motorcycle Forum Post 03-08-2011, 10:12 PM   #14
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

55 deg today, so I was able to spare 2 hours to get some more done on the bike. Dad got bit by the bug and wanted his bike accessible before I disabled mine too much more, so spent the first hour shuffling bikes and tools. But, it did provide me with a nifty trick to help with the oil pan replacement. Engine hoists are fucking awesome.



With the stand down for fall support, and the front end lifted up, the pan is much more accessible. And it looks like a statue of hooliganism, too. Hard to tell with the shadows and sunlight, but the front fender is waist high.



Started fiddling with the subframe because I didn't have enough daylight to complete anything else major, and took the tank off and drained it in preperation for some body work. This tank is enormous. For reference, it's sitting on a 5 gal. can. (18.92 liters, you blokes).



I'm not too sure how I'm going to make this subframe fit, nothing matches to the frame. It looks like I'll have to notch the subframe, and do some cutting and welding on the rear section of the bike frame too. I was concerned with how it would look, but with the plastic on, not much is visible. I'll be modifying the frame tubes that are visible underneath the subframe to help support the weight from the seats. I'm hoping to have as much space between the tire and the bottom of the subframe as possible, as if it's just floating.





If anyone has any suggestions or ideas on how to proceed with the subframe installation, please post em up in the discussion thread. I'll be getting into more detail on the subframe soon, after the pan and clutch covers are replaced. I'll be replacing as much of the damaged parts as I can before I begin too much modification.
More to come soon.

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Old Streetfighter Motorcycle Forum Post 03-11-2011, 12:32 PM   #15
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

Well, another round of snow has dropped 6" here, but it didn't stop UPS from dropping off an undertail pan and dual R1 mufflers. I think I've figured out how to make the subframe fit too, but I need some advice on the structural strength of my plans.



This shows the rear of the frame, where the stock subframe attaches. I believe I am going to cut off the upper cross bar between the rails, and cut off the lower rail from the front pegs to the cross rail, leaving only the upper rails for support, which will be cut and rewelded closer to the center to hide under the subframe. I'll then weld the crossbar I removed onto the frame above the front pegs for additional support, and use the rest to extend the upper rails back for more support. The battery box is already gone as the subframe has a box already.



In this picture, you can see the subframe almost fits along the frame rails on each side of the tank mounts. I'll use the passenger peg mounting plates that I'll be cutting off, and weld them onto the frame rails in order to mount the subframe. This will leave a small gap between the rear of the tank and the front of the seat, which I'm sure my homies at Alchemy Upholstery (www.alchemyupholstery.com) can help with. I'm going to draw some stuff up and post it for some expert examination when my daughter goes down for a nap. Sparks! Fire! Molten Metal!

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Old Streetfighter Motorcycle Forum Post 03-11-2011, 06:52 PM   #16
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

Ok, so if you haven't already had a laugh at my expense for starting this project, you will now when you see my super remedial drawing expertise.
So in advance, fuck you all.


This is (or, is supposed to be) the exisitng frame setup rear of the tank mounts. The top rails end in the upper subframe mounts, and the lower subframe mounts to the plates on the lower rails where the rear peg brackets are. Those plates will become the mounting surfaces for the new subframe after they're relocated to the tank mount area.


Here's the idea for the new frame section. I don't believe that this will compromise the structural integrity of the frame, however, please speak up if you feel differently. As far as I can tell, the rear rails that I plan to remove have no structural significance outside of the lower subframe supports. Since that subframe is gone, they too can go. The top rails will be doubled up and angled to provide proper seating position. The R1 subframe will connect to the plates beside the tank mount, and will be bolted through the bottom into the double frame rails as well. This should give me plenty of space to fabricate a new undertail exhaust, yet still have some space to hide wiring and such. Feel free to chime in with any ideas or criticisms. I've never worked on a bike before, but I have extensive welding and mechanical abilities. Motorcycles are about the only thing I haven't worked on, including planes, trains, and heavy equipment. I may have to modify the tank as well, depending on how far forward the subframe mounts. But we'll see. For now, these are just ideas. If anyone has any better ones, please send them my way. I think I'll be able to reuse what I cut out to extend the upper rails. Don't forget, I need enough support to hold a passenger.

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Old Streetfighter Motorcycle Forum Post 03-12-2011, 04:07 PM   #17
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

This project just got a lot easier. Dad just called and said he bought an Eastwood 200amp tig welder. Score.

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Old Streetfighter Motorcycle Forum Post 03-21-2011, 07:43 PM   #18
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

Quick, no picture update. Rear brake cylinder is off, broken brake pedal bracket and foot peg is off, and oil pan is off. Tomorrows plan is to get gasket dealer, brake cleaner, oil, and coolant. Once the new pan is on, I'll be playing with the new tig in preparation to start chopping the frame. Pictures tomorrow, the plan is to have the new R1 subframe installed, and be able to get the engine running by Sunday. The weather is here. Time to do work and get riding.

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Old Streetfighter Motorcycle Forum Post 03-26-2011, 06:29 PM   #19
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

I actually had a whole day off, so I shipped my daughter off to the inlaws for the weekend, and devoted my day to the bike. I'll divide my progress into several posts. I started about 10am this morning, and I'll take you through my day. First off, it's cold. And when I say cold, I mean cold as a witches tit cold.


And there's no heat in the garage. No matter, I've come prepared. I want to ride, and I need to work.


Carhartt's, mother sucka! Keepz yo nutz toasty. But when I said prepared, I mean prepared. I always have a backup plan.


A little Irish Cream with my coffee, then so many quality choices, it's hard to decide. Backup plan executed. Drink til your numb. Then you don't mind the cold. Somehow, you even manage to lose your coat. And yes, that's 10:47 AM. Don't judge me, I work midnights. This is like my 8pm. Yinz just jealous.

Gotta Have some inspiration.


So first step, cracked oil pan off. New to me old oil pan cleaned up, flanges scuffed, plus supplies in the sun to warm up. Kinda hard to cure gasket sealer when it's this cold, but I've got time. It'll seal by Fighter Fest.


--Having some issues transferring pictures. I'm working on it.--

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Old Streetfighter Motorcycle Forum Post 03-27-2011, 04:33 PM   #20
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Default Re: mantisz's 94 Kawasaki Concours "Disciple"

OK, finally got the whole picture thing figured out again. So to pick up where I left off, old oil pan is off, new o-rings for the pickup and tubes.


Then the salvaged pan is on, oil cooler lines reattached. New plugs too, someone had stripped out a previous plug and made it into a self tapping oil plug. Glad I was getting a new pan anyways.


Bub bye excess weight.


And outside into the sunlight she goes. Pan is on, oil cooler is back on, and suddenly I get this great (half drunk) idea that I need to try and start this pig. So the goal is set, fire'er up before dark. Or I drink too much and lose my ratchet. (still don't know how it got in the bathroom.)



So I spray it all down with degreaser, drag out the hose, and wash it off. Then off comes the damaged brake lever and switch.


And this was the present I found. And since I bought a new throttle cable, guess which part it doesn't have on it. That's right, the one I need.


Dammit, throttle adjustment is broken. But I still want to start it, I'll pull on the cable if I have to. So I continue towards my goal. Degrease, clean up, and paint the header.


Then wait for it to flash, and paint another coat.


And on goes the header.


New fan to replace the one that was damaged in the crash.


On goes the radiator, filled with coolant.


Next the tank, with some fuel added, and the battery temporarily placed on the swing arm. New brake lever on, switches mounted just to try and start it.


And then, the moment of truth. Rarr Rarr Rarr Rarr Rarr Rarr. Well, it turns over. That's a good sign. Maybe it just has some air in the fuel line. Rarr Rarr Rarr Rarr Rarr Rarr. Shit. Get out my spark tester, good spark to the plugs. OK, gasoline engine, only needs air, fuel, and spark. Getting air, getting spark, not so sure about fuel. Rarr Rarr Rarr Rarr Rarr Rarr. Come on. Rarr Rarr Rarr Rarr Rarr Rarr. Rarr Rarr Rarr Rarr Rarr Rarr. Rarr Rarr Rarr Rarr Raarrrr...Rarrrr.......Rarrrr...........Rarrrrr... .................Click. Fuck. Batteries dead. Oh well. Pushed her back into the garage, put her on the charger, got cleaned up, and realized my back hurt. Alot. Time for shots and a heating pad. Next up is the subframe swap and modifications. After that I'll start the body work, and then wiring. Doesn't look like I'll make my April 1st riding date. Oh well, I'm plugging away. Got a lot of time off in April, a 10 day stretch, so I'll be wrenching on the bike from sunrise to sunset.

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