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My Recent Posts · (19-Jul-08

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A few months ago I completed an engine change-out project with my 2003 Kawasaki Concours.

I bought a 2003 ZRX 1200R in order to take the engine and front forks and transplant them into my Concours. The engine converted to shaft drive fairly easily.

Long story short, I have about 5,000 miles on it already (including a 3,000 mile ride to Colorado and back to California).

Pictures here:

http://community.webshots.com/album/559174986RBxWeD?vhost=community

Picture as it looks today:

These modifications have transfomed this motorcycle into what it should have been from the factory. Greatly improved acceleration and mid-range torque, solid, rigid front end revolutionizing the handling and brakes that stop on a dime and give back nine cents in change.

I'm happy with it even though it took me over a year to get to this point. I wouldn't take a million bucks for it but I'll never do anything like this again (even though I would help others to do the same conversion), I'm getting too old for these sorts of shenanigans.

So, whadaya think?

JMHO

Dan

My Recent Posts · (19-Jul-08

Well done time and patience shows in the end result.
I have ridden the donor bike before and is was no slouch so must be great
in the set up you have. Any plans to refit lower halves of farting just to confuse
people?
RobS

My Recent Posts · (20-Jul-08

RobS wrote:
Well done time and patience shows in the end result.
I have ridden the donor bike before and is was no slouch so must be great
in the set up you have. Any plans to refit lower halves of farting just to confuse
people?
RobS

I started fitting the lower fairing parts (there were a few minor interference areas) and got almost done when I realized it looks so much better in naked form. I do intend to finish the fitting (I have one part left to fit) so I will have full coverage available for lousy weather rides. Probably not until next winter when we plan three day excursions that have rain storm potential.

I want to show up at a dealer and ask him if he knows where I can find parts for a ZGRX 1200 Concours. There is one about an hour south of where I live who thinks they are smartest, best dealer on the planet (too big for their own britches). It would be fun to buffalo him a bit.

JMHO

Dan

My Recent Posts · (20-Jul-08

Dan - you've done an excellent job mate - looks awesome!!! I think you're right, looks good semi naked - hey, for that much effort you want to show it of!! Like what you've done with the mufflers too.

My Recent Posts · (20-Jul-08

Excellent job Dan.
I rode an A1 semi naked for 3 years and loved it.
Never got hot in summer and was warm in winter. Great coversion piccs.
Michael
ps: I can just see the dealer now. Uhh

Pity you are not over here or I know exactly where I would take it for question time.

My Recent Posts · (20-Jul-08

Please take a camera with you when you show the dealer just so we can see the look on his face

My Recent Posts · (20-Jul-08

Brilliant Dan, fully faired it would be a real sleeper.

Pull up next to a GTR1000 and disappear into the distance at the green light!

A job well done and beautifully documented

My Recent Posts · (21-Jul-08

Fantastic job Dan, I read about the conversion on the COG site.
Very impressive, to say the least.
How you find the time gets me.

Along with the Turbo job, of Rev Rider ( Chuck ) Nearly 40 pages!!.
Another link to a funny Lucky Chuck story. http ://forum.concours.org/index.php?topic=45588.0

To think, he had the nous to build a turbo to his bike -- side stand -- bungee -- ironic

After taking the screws out of the fairing thingy, and changing oil, and filter thingamajig,
( yes! I spelled it right, see Spellcheck had it listed, amassed ) the 5 min. job turns into 1 hr. ( ok 2 hrs. )
Then I feel as if I had really accomplished something, but after reading your write up. I am sadly lacking.

The effort you guru, mach, tech, eng., journo, type people go to, to not only create,
but write about it in detail, with pictures, is encouraging.

Just lately I have made the time, to just go browsing through some of COG forum threads, stories, write ups, whatever.
It's going to take years!!.

Anyway, thank you for posting the info on our site, I may have missed out on a great write up,
and not learned a thing.

Still don't know what to do with it, ( all this new found Knowledge ) but I'm sure I'll put it to good use some day.
Until then.

P.S. It's only taken me 1hr and 45 min to write this down,
so if I got off my fat ass, and did something, it could take the rest of my life to write about it.

My Recent Posts · (21-Jul-08

Dan,

Thats really impressive stuff, have wtached your progress on the COG site.
Obvoiusly you have way too much spare time and need to get a hobby.

Cheers Richard

My Recent Posts · (22-Jul-08

David wrote:
After taking the screws out of the fairing thingy, and changing oil, and filter thingamajig,
( yes! I spelled it right, see Spellcheck had it listed, amassed ) the 5 min. job turns into 1 hr. ( ok 2 hrs. )
Then I feel as if I had really accomplished something, but after reading your write up. I am sadly lacking.

David, it you want to become a very accomplished bike mechanic, get a Ducati!

Cheers, Craig

My Recent Posts · (22-Jul-08

Hi Craig,
" Been There, Done That."
Just made me an expert in using Loctite.
Some bikes you should never sell.

P.S. How is the new Corbin seat.

My Recent Posts · (22-Jul-08

Hey David,
Seat collected and fitted, however the tush has not tested it on the road yet.
Looks the dogs bollox though................

My Recent Posts · (25-Jul-08

Thanks so much for the great replies here!

This has been an extremely rewarding project but it certainly helps to have the support of the Concours gurus around this great world of ours!

PLUS, I stand at the ready to assist anyone who wishes to tackle this outstanding upgrade to the classic Concours that we all know and love.

I have a fully documented process that I will gladly share to those that are interested, no charge.

Let's get more of these on the roads, mates!

JMHO

Dan

My Recent Posts · (25-Jul-08

Dan have you thought of making a few bits for the 1400GTR/Concours14 like bug eye light rackets and bracket for the cruise ?

My Recent Posts · (25-Jul-08

btw some may not know but this is Dan Bergmen, creator of a number of items for the 1000GTR/Concours.

http://www.bergmenengineering.com/

My Recent Posts · (28-Jul-08

Aussiedav wrote:
Dan have you thought of making a few bits for the 1400GTR/Concours14 like bug eye light rackets and bracket for the cruise ?

Well, unfortunately, I don't have a C-14 at my disposal in order to come up with any nifty accessories. I can understand the need, though.

If you have any ideas on possible solutions, shoot me an e-mail and I'll put my thinking cap on.

BTW, I have put more than 5,000 miles on the ZGRX since I got it ready for the National Rally in Frisco, Colorado. I haven't had to do anything to it at all, everything is just as it was (no broken parts, loose bolts, leaky anything). It is ready for an oil change and full mechanical and systems inspection, so it will be down for a bit so I can have a very careful look-see.

Also, my wife and I just got back from a superb 300 mile anniversary get-away out to the California coast highway. The Concours performed flawlessly although I was very easy on the loud handle for the wife's comfort. We just got back a couple of hours ago.

JMHO

Dan

My Recent Posts · (29-Jul-08

Any of us want to try it.
Is this the right engine Link

My Recent Posts · (29-Jul-08

chasnee wrote:
Any of us want to try it.
Is this the right engine Link

No, that is a ZX1200, not a ZRX1200R. It is a sport bike while the ZRX is a naked standard.

JMHO

Dan

My Recent Posts · (29-Jul-08

Oops, sorry

ZRX also seems to have a better motor, all alloy cylinders etc.
Can't find a hp rating for it though.

My Recent Posts · (30-Jul-08

chasnee wrote:
Oops, sorry
ZRX also seems to have a better motor, all alloy cylinders etc.
Can't find a hp rating for it though.

Here is a chart I made with published figures:

Sort of instigating, isn't it?

Also, one thing to keep in mind is that these figures are for a bone-stock ZRX. It is really easy to pump this mill up in any number of ways (the Rex crowd are seriously deranged horsepower and torque freaks), from big bore kits to cams, h.c. pistons, turbos, etc.

What I have is ground floor power and I could not be happier, goes like all hell.

JMHO

Dan

My Recent Posts · (30-Jul-08

Stiletto 150 wrote:

Also, one thing to keep in mind is that these figures are for a bone-stock ZRX. It is really easy to pump this mill up in any number of ways (the Rex crowd are seriously deranged horsepower and torque freaks), from big bore kits to cams, h.c. pistons, turbos, etc.
Dan

Dan, As I mentioned to you on COG many months ago, you won't be disappointed with ZRX and it would seem that you have now "seen the light ". While there are some ZRX devotees who are mild mannered enthusiasts who only ride the ZRX to church on Sundays and never exceed 3000 rpm, there are not many.

The ZRX is ultimate "sleeper". It makes a perfectly good touring bike with the addition of some soft saddle bags, yet can stick with the majority of tupperware sports bikes through the back country hills on a Sunday morning sprint.

Modifying a ZRX is like a desease. It all starts with fiddling with the stock jetting, then its Ivan's needles and a then full exhaust system and low and behold you have hp and torque gains through the complete rev range with probably another 20 hp on the top. Then you get serious, HC pistons, big bore kit, lightened crank, ZZR cams, until you finally fall ove rthe edge and get the turbo. At the moment, I am still saving the pennies for the crank/cam/big bore mod.

Mind you, while I have modded my ZRX a bit, Ive tried to balance the power gains with inprovements in the handling. Decent tyres ( I run a Metzler M3/Z6 combo) and the front forks, which I see you have also grafted onto your ZGRX, really do need Racetech Gold valves (pre-2004 models only, post 2004 cant be reworked) plus new fork springs and while you are at it, one of Greg Couch's fork braces does make a difference (IMHO).

The other thing that you may seriously want to consider is fitting one of Kwick's Tip Over switches ( which is a modified R1 switch ). The ZRX engine has a nasty habit of running #3 conrod bearing if the engine is left running on its side for more than a few seconds as the oil pump starves.

Only request I have is that if anyone ( here in Oz or in the US ) decides to duplicate your project, please use a crashed out ZRX and not a roadworthy bike. I saddens my heart to see a perfectly good ZRX dismantled.

Author	Comment
Stiletto 150	ZGRX 1200 Concours Project	Lead	[-]
Posts: 9 (19-Jul-08 11:11 AM) Still Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Tags : None A few months ago I completed an engine change-out project with my 2003 Kawasaki Concours. I bought a 2003 ZRX 1200R in order to take the engine and front forks and transplant them into my Concours. The engine converted to shaft drive fairly easily. Long story short, I have about 5,000 miles on it already (including a 3,000 mile ride to Colorado and back to California). Pictures here: http://community.webshots.com/album/559174986RBxWeD?vhost=community Picture as it looks today: These modifications have transfomed this motorcycle into what it should have been from the factory. Greatly improved acceleration and mid-range torque, solid, rigid front end revolutionizing the handling and brakes that stop on a dime and give back nine cents in change. I'm happy with it even though it took me over a year to get to this point. I wouldn't take a million bucks for it but I'll never do anything like this again (even though I would help others to do the same conversion), I'm getting too old for these sorts of shenanigans. So, whadaya think? JMHO Dan Last Edited By: Stiletto 150 31-Jul-08 5:39 AM. Edited 3 times.
RobS	Re: ZGRX 1200 Concours Project	#1	[-]
Posts: 256 (19-Jul-08 9:42 PM) I Live Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Well done time and patience shows in the end result. I have ridden the donor bike before and is was no slouch so must be great in the set up you have. Any plans to refit lower halves of farting just to confuse people? RobS
Stiletto 150		#2	[-]
Posts: 10 (20-Jul-08 4:41 AM) Still Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	RobS wrote: Well done time and patience shows in the end result. I have ridden the donor bike before and is was no slouch so must be great in the set up you have. Any plans to refit lower halves of farting just to confuse people? RobS I started fitting the lower fairing parts (there were a few minor interference areas) and got almost done when I realized it looks so much better in naked form. I do intend to finish the fitting (I have one part left to fit) so I will have full coverage available for lousy weather rides. Probably not until next winter when we plan three day excursions that have rain storm potential. I want to show up at a dealer and ask him if he knows where I can find parts for a ZGRX 1200 Concours. There is one about an hour south of where I live who thinks they are smartest, best dealer on the planet (too big for their own britches). It would be fun to buffalo him a bit. JMHO Dan
Roba		#3	[-]
Posts: 815 (20-Jul-08 12:13 PM) No Keys Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Dan - you've done an excellent job mate - looks awesome!!! I think you're right, looks good semi naked - hey, for that much effort you want to show it of!! Like what you've done with the mufflers too. Cheers - RobA 2003 1000GTR
sirion06		#4	[-]
Posts: 1454 (20-Jul-08 1:32 PM) I Live Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Excellent job Dan. I rode an A1 semi naked for 3 years and loved it. Never got hot in summer and was warm in winter. Great coversion piccs. Michael ps: I can just see the dealer now. Uhh Pity you are not over here or I know exactly where I would take it for question time.
BobS		#5	[-]
Posts: 585 (20-Jul-08 3:03 PM) I Live Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Please take a camera with you when you show the dealer just so we can see the look on his face
Sebastionbear		#6	[-]
Posts: 198 (20-Jul-08 9:42 PM) failure to launch Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Brilliant Dan, fully faired it would be a real sleeper. Pull up next to a GTR1000 and disappear into the distance at the green light! A job well done and beautifully documented
David		#7	[-]
Posts: 123 (21-Jul-08 2:50 PM) Hangs Out Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Fantastic job Dan, I read about the conversion on the COG site. Very impressive, to say the least. How you find the time gets me. Along with the Turbo job, of Rev Rider ( Chuck ) Nearly 40 pages!!. Another link to a funny Lucky Chuck story. http ://forum.concours.org/index.php?topic=45588.0 To think, he had the nous to build a turbo to his bike -- side stand -- bungee -- ironic After taking the screws out of the fairing thingy, and changing oil, and filter thingamajig, ( yes! I spelled it right, see Spellcheck had it listed, amassed ) the 5 min. job turns into 1 hr. ( ok 2 hrs. ) Then I feel as if I had really accomplished something, but after reading your write up. I am sadly lacking. The effort you guru, mach, tech, eng., journo, type people go to, to not only create, but write about it in detail, with pictures, is encouraging. Just lately I have made the time, to just go browsing through some of COG forum threads, stories, write ups, whatever. It's going to take years!!. Anyway, thank you for posting the info on our site, I may have missed out on a great write up, and not learned a thing. Still don't know what to do with it, ( all this new found Knowledge ) but I'm sure I'll put it to good use some day. Until then. P.S. It's only taken me 1hr and 45 min to write this down, so if I got off my fat ass, and did something, it could take the rest of my life to write about it. David Adelaide. GTR 1000 ---*"POSH Bike"* Last Edited By: David 21-Jul-08 4:59 PM. Edited 1 times.
vk5zlr		#8	[-]
Posts: 287 (21-Jul-08 9:01 PM) I Live Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Dan, Thats really impressive stuff, have wtached your progress on the COG site. Obvoiusly you have way too much spare time and need to get a hobby. Cheers Richard
Sebastionbear		#9	[-]
Posts: 201 (22-Jul-08 7:10 AM) failure to launch Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	David wrote: After taking the screws out of the fairing thingy, and changing oil, and filter thingamajig, ( yes! I spelled it right, see Spellcheck had it listed, amassed ) the 5 min. job turns into 1 hr. ( ok 2 hrs. ) Then I feel as if I had really accomplished something, but after reading your write up. I am sadly lacking. David, it you want to become a very accomplished bike mechanic, get a Ducati! Cheers, Craig
David		#10	[-]
Posts: 128 (22-Jul-08 1:19 PM) Hangs Out Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Hi Craig, " Been There, Done That." Just made me an expert in using Loctite. Some bikes you should never sell. P.S. How is the new Corbin seat. David Adelaide. GTR 1000 ---*"POSH Bike"*
Sebastionbear	The Corbin seat is fitted!	#11	[-]
Posts: 204 (22-Jul-08 2:31 PM) failure to launch Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Hey David, Seat collected and fitted, however the tush has not tested it on the road yet. Looks the dogs bollox though................
Stiletto 150		#12	[-]
Posts: 11 (25-Jul-08 1:31 PM) Still Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Thanks so much for the great replies here! This has been an extremely rewarding project but it certainly helps to have the support of the Concours gurus around this great world of ours! PLUS, I stand at the ready to assist anyone who wishes to tackle this outstanding upgrade to the classic Concours that we all know and love. I have a fully documented process that I will gladly share to those that are interested, no charge. Let's get more of these on the roads, mates! JMHO Dan
Aussiedav		#13	[-]
Posts: 3980 (25-Jul-08 1:44 PM) FarRider Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Dan have you thought of making a few bits for the 1400GTR/Concours14 like bug eye light rackets and bracket for the cruise ? Davo 1400GTR "Roo" & 1000GTR "Griff" IBA #22575 - Davo's Pages
Aussiedav		#14	[-]
Posts: 3981 (25-Jul-08 2:03 PM) FarRider Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	btw some may not know but this is Dan Bergmen, creator of a number of items for the 1000GTR/Concours. http://www.bergmenengineering.com/ Davo 1400GTR "Roo" & 1000GTR "Griff" IBA #22575 - Davo's Pages
Stiletto 150		#15	[-]
Posts: 12 (28-Jul-08 9:00 AM) Still Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Aussiedav wrote: Dan have you thought of making a few bits for the 1400GTR/Concours14 like bug eye light rackets and bracket for the cruise ? Well, unfortunately, I don't have a C-14 at my disposal in order to come up with any nifty accessories. I can understand the need, though. If you have any ideas on possible solutions, shoot me an e-mail and I'll put my thinking cap on. BTW, I have put more than 5,000 miles on the ZGRX since I got it ready for the National Rally in Frisco, Colorado. I haven't had to do anything to it at all, everything is just as it was (no broken parts, loose bolts, leaky anything). It is ready for an oil change and full mechanical and systems inspection, so it will be down for a bit so I can have a very careful look-see. Also, my wife and I just got back from a superb 300 mile anniversary get-away out to the California coast highway. The Concours performed flawlessly although I was very easy on the loud handle for the wife's comfort. We just got back a couple of hours ago. JMHO Dan
chasnee		#16	[-]
Posts: 130 (29-Jul-08 7:09 AM) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Any of us want to try it. Is this the right engine Link Charlie 1000GTR. Luminous Vintage Red or Wineberry, CCS100 Cruise Control, Airhawk cushions, Home made windscreen. Hella FF50 spots FarRider #99 GTR-AUS #209 Ulysses #51307 My Album
Stiletto 150		#17	[-]
Posts: 13 (29-Jul-08 3:00 PM) Still Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	chasnee wrote: Any of us want to try it. Is this the right engine Link No, that is a ZX1200, not a ZRX1200R. It is a sport bike while the ZRX is a naked standard. JMHO Dan
chasnee		#18	[-]
Posts: 131 (29-Jul-08 5:39 PM) Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Oops, sorry ZRX also seems to have a better motor, all alloy cylinders etc. Can't find a hp rating for it though. Charlie 1000GTR. Luminous Vintage Red or Wineberry, CCS100 Cruise Control, Airhawk cushions, Home made windscreen. Hella FF50 spots FarRider #99 GTR-AUS #209 Ulysses #51307 My Album
Stiletto 150		#19	[-]
Posts: 14 (30-Jul-08 4:11 AM) Still Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	chasnee wrote: Oops, sorry ZRX also seems to have a better motor, all alloy cylinders etc. Can't find a hp rating for it though. Here is a chart I made with published figures: Sort of instigating, isn't it? Also, one thing to keep in mind is that these figures are for a bone-stock ZRX. It is really easy to pump this mill up in any number of ways (the Rex crowd are seriously deranged horsepower and torque freaks), from big bore kits to cams, h.c. pistons, turbos, etc. What I have is ground floor power and I could not be happier, goes like all hell. JMHO Dan
Murphyau		#20	[-]
Posts: 117 (30-Jul-08 9:46 AM) I Live Here Reply Quote More My Recent Posts Message Me Connection Blocking Invite Ignore User's Posts	Stiletto 150 wrote: Also, one thing to keep in mind is that these figures are for a bone-stock ZRX. It is really easy to pump this mill up in any number of ways (the Rex crowd are seriously deranged horsepower and torque freaks), from big bore kits to cams, h.c. pistons, turbos, etc. Dan Dan, As I mentioned to you on COG many months ago, you won't be disappointed with ZRX and it would seem that you have now "seen the light ". While there are some ZRX devotees who are mild mannered enthusiasts who only ride the ZRX to church on Sundays and never exceed 3000 rpm, there are not many. The ZRX is ultimate "sleeper". It makes a perfectly good touring bike with the addition of some soft saddle bags, yet can stick with the majority of tupperware sports bikes through the back country hills on a Sunday morning sprint. Modifying a ZRX is like a desease. It all starts with fiddling with the stock jetting, then its Ivan's needles and a then full exhaust system and low and behold you have hp and torque gains through the complete rev range with probably another 20 hp on the top. Then you get serious, HC pistons, big bore kit, lightened crank, ZZR cams, until you finally fall ove rthe edge and get the turbo. At the moment, I am still saving the pennies for the crank/cam/big bore mod. Mind you, while I have modded my ZRX a bit, Ive tried to balance the power gains with inprovements in the handling. Decent tyres ( I run a Metzler M3/Z6 combo) and the front forks, which I see you have also grafted onto your ZGRX, really do need Racetech Gold valves (pre-2004 models only, post 2004 cant be reworked) plus new fork springs and while you are at it, one of Greg Couch's fork braces does make a difference (IMHO). The other thing that you may seriously want to consider is fitting one of Kwick's Tip Over switches ( which is a modified R1 switch ). The ZRX engine has a nasty habit of running #3 conrod bearing if the engine is left running on its side for more than a few seconds as the oil pump starves. Only request I have is that if anyone ( here in Oz or in the US ) decides to duplicate your project, please use a crashed out ZRX and not a roadworthy bike. I saddens my heart to see a perfectly good ZRX dismantled. Regards, Steve Sydney, Oz. Last Edited By: Murphyau 30-Jul-08 10:28 AM. Edited 4 times.

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ZGRX 1200 Concours Project

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