'95 ZX11-D3 & '99 ZRX11-C3 stuff

[ZRX61]

Started by draining the oil & dropping the filter.. then discovered the oil filter o-ring is not the correct one. Will order one tomorrow.



Decided to press on with the alt/starter chain tensioner upgrade. Not sure how, but the clutch cover gasket came off intact with the cover, no pieces stuck to the cases. That's a first.



Removed tensioner, now I need to watch the YT *how to* video again (it really is a piece of piss to do this, but it's been a while since I did the ZRX11)



Removed metal splinter from finger tip..

Will avoid the temptation to re-use the clutch cover gasket, already have a new one that's been in my toolbox for over a decade... This means scraping the old one off the clutch over which will most likely use up 98% of the time this project takes... Plus I get to use the spiffy gasket scrapers I bought a while back.

This doodad is the perfect thing for prying covers off...



Decided to see if I have a spare oil filter o-ring... nope, must have used it on the ZRX11.
Discovered I actually have an OEM brand spanking new complete tensioner that I must have bought 18 years ago. This was while I working at a Kaw dealer & stocked up on *stuff* at dealer cost while I had to opportunity. That went back in the stash, will put the mod on the one that came off the bike.

[ZRX61]

It's been 24 hours, will put the drain bolts back in today (ZX11's have 2)... & make a start on scraping the goddamn gasket off the clutch cover.

Edit:
30 minutes with the spiffy gasket scrapers. (helps if you can sharpen chisels etc)

[ZRX61]

Job jobbed...red snot is added security for the Ping!FuckIt!



Ordered O-rings & gaskets

[ZRX61]

When I did the ZRX11 the manual called for blue Loctite & 87in/lb for the two bolts. The ZX11 manual just called for blue Loctite, no torque listed. It got 87in/lb

[ZRX61]

Clutch cover may have been washed in the kitchen sink this evening....

[ZRX61]

Cover back on, minus the sound deadener nonsense...



Decided to spiff up the drain tube..

[ZRX61]

Further to the ZX11 manual not listing torque specs for the tensioner bolts, but the ZRX11 manual did: Discovered the same deal for the clutch cover bolts. ZX11 manual just stated blue goop on the 4 front most bolts, but no torque listed. ZRX manual stated blue goop on the same 4 bolts & torque all of them to 87in/lb.

[Rockburner]

Further to the ZX11 manual not listing torque specs for the tensioner bolts, but the ZRX11 manual did: Discovered the same deal for the clutch cover bolts. ZX11 manual just stated blue goop on the 4 front most bolts, but no torque listed. ZRX manual stated blue goop on the same 4 bolts & torque all of them to 87in/lb.

Basically the same engine though, aren't they?

[ZRX61]

Basically the same engine though, aren't they?

Yup, Mama Kaw made that series of engines from the '84 GPz900R to the '16 ZRX1200 DEAG & used it across 15 or 16 different models.

[ZRX61]

Parts are in at the dealer. One O ring for the ZX11 filter plate, one spare & 2 clutch cover gaskets for the stash. Will be in that neighborhood (46 miles away) when we pick up the Explorer ST from the shop next week (allegedly).

[ZRX61]

Got ambitious this morning, dropped rear wheel & pulled the eccentrics to investigate *grindy* feel. Felt like they were full of gravel.
No gravel, but the coating was gone from the outside. Gave then the benefit of a whizz with the deburring wheel on the bench grinder. Much better now.
Didn't get an *after* pic, but this was the *before* (ignore screw)

[ZRX61]

Picked up the parts order this morning, reassembled all the filter gubbins & installed it. May get ambitious & put some oil in it...

[ZRX61]

Got ambitious & put some oil in it...

[ZRX61]

Upgraded 1 bolt & 3 self-tappers & the associated j-clips/speed nuts for allen head spiffery & new speed nuts





Guards will be coming off when it isn't 108 fucking degrees in the garage for a squirt of black Hammertone rattle can, maybe some black radiator paint on the radiator & oil cooler too if I'm feeling generous

[ZRX61]

Tinkered:

1) Decided to pull the stone guards on the ZX11 that protect the radiator & oil cooler & give them the benefit of some black hammertone before I put the fairing lowers back on the bike.
2) Steamed the radiator & oil cooler, looked great, decided not to paint them.
3) Questioned my choices in life & my sanity as I spent 20 goddamn minutes trying to get one frigging screw back in. I could either hold the screw OR hold the flashlight in the right place... but couldn't point the flashlight at the hole while holding the screw or the bit. FFS.
4) Picked up the fairing lowers... oh, another stone guard..
5) Removed & painted the 3rd stone guard.
6) Reinstalled 3rd stone guard.
7) Installed the fairing lowers.

Later:
Detail the fairing lowers to remove fingerprints etc.

Made a call to pick up some blue gas..

Tomorrow:
Pottering... There's already been some minor pottering as all the tools are now in the same baking pan on the bench, but further pottering is required.

Somewhat cleaner fins on the rad etc & some fresh paint on the stone guards (before the fairing etc got spiffed)

[Count Steer]

3) Questioned my choices in life & my sanity as I spent 20 goddamn minutes trying to get one frigging screw back in. I could either hold the screw OR hold the flashlight in the right place... but couldn't point the flashlight at the hole while holding the screw or the bit. FFS.

Headtorch.

[ZRX61]

Headtorch.

It was sitting on the bench, forgot I have one... even though I used it just the day before. FFS

[ZRX61]

Following on from the height adjustment by fitting ZX6 dogbones, I decided to see where it stood with the eccentrics flipped to the lower position which raises the rear end. Was hoping it would be a bit higher, but lower than it was with the stock ZX11 dogbones.
Not what I wanted, so today the eccentrics are back in the higher position after yesterday's test ride...

Took it for a hoon along the San Andreas which is pretty much straight for several miles, but with a few left/right or right/left kinks thrown in. Most of the kinks are posted 45mph, but as I know the road I can zip through them around 100mph.

Or rather, on the ZRX11 I can, trying to blast the longer/heavier ZX11 through the kinks at that kinda speed reminded me of just how much more bloody effort it takes to change direction on the ZX11 than the ZRX11. I whoa'd up a bit after almost scaring myself a second time, scared a couple of indecisive squirrels too.

[Rockburner]

Headtorch.

It was sitting on the bench, forgot I have one... even though I used it just the day before. FFS

Been there, done that.

Tbh I prefer a work light. I have a nice little Ikea bedside light which has a big "crocodile" clip type of mount, and a 50cm stiff flex, so it's ideal for getting light right where you want it.

[ZRX61]

Faffed about with the right switch cluster. Got an intermittent electrical gremlin on the loose in the starter circuit.
Will investigate deeper if needed after Sunday's ride.. which will involve the tank coming off (A piece of piss compared to a ZRX11)
Ordered new plug well & cam cover gaskets so I can check valve clearances while I have the tank off, it's also getting a carb sync. They probably won't be here until next week

Sunday's ride is gonna be a bit brutal. ZX11's are leg roasters at the best of times & the forecast for Sunday is 108-110deg. FFS.