Almost Ready For 2013

As I mentioned in my previous post, the Ohlins KA606 had clearance issues and didn't fit the bike without modifications. My fall back plan was to use a Ohlins KA345 shock instead which was designed for the 04-05 ZX10R.

KA606

KA345

The reason the KA606 did not fit was due to the design of the 06-07 ZX-10R for which it was made. The 06-07 ZX-10R was the only model with a big heavy under tail exhaust on the right side of the bike so the reservoir had to be offset quite a bit to the left to clear the hot pipes. The KA345 on the other hand was made for the 04-05 ZX-10R which had a conventionally mounted exhaust. This conservative exhaust position allowed for a nuetral reservoir position.

I phoned Ohlins USA and spoke with a gentleman by the name of Jerry Wohlgemuth. We worked out over the phone that the shock mounting hardware from the KA601 which was designed specifically for the ZX-7R would fit the KA345. This meant that I wouldn't need to modify any parts like I had to do initally with the KA606!

Bottom clevis with unmodified shock linkage sleeve

Top mount bushing with ZX-7R upper shock mount

KA601 clevis compared to the KA606's

KA601 top mount bushings compared to the KA606's

The top mounting bushings were little tricky to get out. They were a split design that needed to be hammered out with a drift. A nice drift with sharp corners were neccessary to avoid damage.

Drifting out the split bushings

Bushings hammered out

One specification of ZX-10R shocks in general that worried me was the shock length. ZX-10R shocks in general were 338mm tall vs 348mm for the ZX-7R. The 10mm height difference could have a significant impact on handing. While it was possible to make up for this height difference with shorter shock linkage arms (AKA dog bones) and the ZX-7R upper shock mount, I thought it was best to dial out as much of the difference in shock lengths as possible on the shock itself.

Although it was possible to get the KA345 shock length to match the OEM item, the bottom clevis needed to be turned out right to the limit of what the manual said was safe. I decided safety was more important than razor sharp handling and turned the clevis in a few turns.

12 exposed threads is the maximum adjustment for this clevis

With the neccessary adjustments made, the shock slid into the bike through the top with the battery tray removed.

While I have yet to ride the bike with the KA345 installed, I can report today that the Ohlins is much lighter than the stock shock.

Yes sir, thats a whole 1.5lbs saved. I'm not sure if this is sprung weight or unsprung weight but every ounce counts right?

Another little weight savings thing I did was use the axle from a 06-07 ZX-10. Recall that the FG352 I have on my bike right now were designed for that bike.

Even though the ZX-10 axle required sleeves and a special Ohlins nut, it still managed to be lighter. Not much but once again every ounce counts... and this time I'm sure it's unsprung weight. Unfortunately the weight savings here may be balanced out by these little beauties.

While these Muzzy block off plates are lighter than the entire clean air injection system, they are heavier than the OEM covers.

Even though the block off plates themselves were heavier than the OEM covers, I ditched the OEM reed valves. The instructions that came with the Muzzy block off plates said to leave them in place but I figured the only reason for that was to create a good squish seal with paper gaskets. Since I hated paper gaskets almost as much as I hated getting kicked in the nuts, I decided to use a liquid gasket instead.

My buddy Alok helping me scrape off the paper gasket

Liquid semi-drying Three Bond 1194 sealant

Muzzy block off plates installed

These plates clean up the engine bay nicely

The accute reader will notice I am running CVK carbs because I'm still sourcing some float bowls for my FCRs. More than anything else though, I'm looking forward to just riding the bike this season and not getting caught up in projects mid-season.

The only major component that I need before the bike is road-worth is a new set of triples from Dan Harvy because the original ones had some chatter marks in the lower right bore which caused clamping issues. Dan's hard at work getting me a new set so I'm very excited.

Here are some rainy pics of the bike as it sits now. Enjoy.

Small Details

To say that it has been a while since I've updated this blog is an understatement for which there is no sufficient adjective. Let's start with the biggest update first.

That's right, I'm a dad now! My wife gave birth to our son Calvin in the middle of January. He doesn't do much beyond eating, sleeping laughing and discharging adult quantities of doo doo.

Of course there has been a lot of stuff going on with the bike as well. I'll start where my previous post left off. The Ohlins KA606 didn't fit the bike! A big dissapoinment.

The nub pictured above held one of four chain guard screws. I ground the nub off but then realized the shock preload adjuster still fouled the subframe on big shock compressions. While it was possible to have relocated the adjuster with a longer hydraulic line, it would have neccessitated a rebuild of the shock's entire hydraulic system. I definately did not want to do that so I chose to order an Ohlins KA345, which was well known to fit the ZX-7R (the KA606 was a bit of a gamble)

With the KA345 ordered, I focused my attention to other items on the bike like the new motor I had Gord Bush build for me last year.

first we tear it down ...

... and then we build it up

so clean

the headers installed

the cooling equipment and muffler installed

While the KA345 was still in the mail, I took on a number of small projects. For starters, I polished the engine covers.

here you can see the +4 Vance and Hines advancer in the new motor

Permatex gasket remover working hard

lots of baking soda

the clutch cover sight glass was damaged by the gasket remover so a new one was needed

I also had some of the more visible brackets powder coated. I didn't bother with the mirror and instrument brackets because they would be replaced with aluminum items in the near future.

brackets as they were removed from the bike

I replaced the throttle cable and some fuel line as well.

throttle cables

fuel lines

The new motion pro made a huge difference to the feel of the throttle. For $30 they are definately big bang for buck. New throttle cables will be a part of my regular maintenance for now on. The new fuel lines replaced existing line which connected the gas tank to the fuel filter. The new lines are longer which allows the tank to be pulled off the bike and set near by as an auxillary fuel source. The new lines are also thicker and almost impossible to pinch or kink.

The last thing I had finally gotten around to was sourcing a one piece fender.

I'm not sure which bike this fender was based off of but the sides of the fender were textured and not smooth so I definately didn't want to paint it. As a temporarily fender solution, I borrowed a spare that Chris had lying around.

That's all for now. I'll post updates of the Ohlins shock sometime soon.