CSR1000 Project Build

first off , i've not been on here for quite a while so ,apologies for that , and secondly this thread is massive and i've spent all morning looking through it , personally i really dislike the styling of the CSR and did wonder what your project would end up looking like .. Congratulations on the outcome , great stance and what a difference to it's original appearance ..... a few things i would like to offer my appreciation for , the seat looks fantastic , really nice job . the speedo mount is another great job well executed and the tail piece looks the business too .and the colour is great . id like to offer a couple of ideas to your problem of the chain touching the swingarm , i used the largest sprockets i could fit on mine , possibly a 17 tooth front sprocket and 46 tooth rear , i would have to check ,but i had to modify the front sprocket guard to get the front one on . i see yours was broken already . this gave me a bit of extra clearance . I also used a piece of stainless steel as a chain slider on top of the swingarm bridge to stop the chain eating into the ally .. you need as much clearance as possible at the bridge , when you shut the throttle the slack in the chain run is suddenly at the top of the chain run and what looked like clearance isn't enough ..... eventually i had to channel the swingarm bridge area and get a piece welded back in , luckily i can weld ally so i did it myself . also your chain is a long way off your rear tyre and you could move it over to gain some clearance for the chain / rear shock area , you only need a little gap , when the wheel is spinning centrifugal forces make the tyre narrower and increase the clearance . I also ground a small area away on the rear spring seat , every little helps . alternatively you could swap the swingarm again ! 2001 ZRX swingarm is a relatively straight forward conversion , already has twin shock mounts and has more clearance at the bridge area .. and it looks good IMO..

Wow Kenty. Thanks very much. A nice positive post to start the new year with. Im glad youve enjoyed the build and congrats on your stamina.
Taking your points on the swingarm,I see what you mean about the slack when the throttle is closed. More reason to sort it out.I have shaved the original rubber slider from the GSXR and Im going to mount that for now.I know its not the best fix but its only temporary.I just want to get the bike running and worry about the swingarm later. Its not the time of year to be out clocking up the miles on any bike,let alone a freshly rebuilt bike.
I did look at ZRX arms but theyre up there at 250-300 quid which is way out of my budget now.I do like the idea of channeling the arm that Ive got but I cant weld aluminium. So to get that done (and get it repowdercoated) would probably be 250quid(ish).
The sprockets,Ive thought about. The front will have to stay as it is because thats an offset jobby. Ill have a word with my local shop and see if hell swap me the rear one for something bigger. Though from looking at the line,I think itll make very little difference to the clearance.
The clearance at the shock might not be as problematic as I thought, and again Ive stopped losing sleep over it. If there is going to be an issue,I can turn the rear sprocket around (the back side is recessed) which could give me a couple of mm extra.

So,the situation now is that I have to clean up the points and auto advance. Get the cases fitted. HT cables and spark plugs.Battery earth lead.Carbs put together and mounted. Brakes bled.Oil and petrol.Hydraulic clutch hose fitted and clutch set up. Speedo cable fitted.
Thats it ( I think)
Im still waiting on the speedo cable and the carb jets and I still have to order the clutch hose. Other than that,I have everything I need.
Will keep you posted.
Oh and the posty brought me this


Bling Bling.

Nice Moriwaki's

When are you planning the first start?
Eric

Depending on work and if/when the rest of the parts turn up,Im hoping to be pressing that button sometime next week.Weekend at the latest.

Got the jets yesterday so Ive been busy sorting the carbs.I got some nice new rubbers to make things easier for mounting

Any ideas on whats going on here? Seems to be a hole that is exposed. Is that normal?

Another question. What are these rubber rings for? They sit in a recess under the gasket with no apparent use.Can I do without them??(Im missing 2 of them)
I also fitted the chain guide(?) Swingarm protector(?). I ground it down with a belt sander to make it as slim as possible. Ill use it for now until I get the swingarm situation sorted.


Other than that,I got a load of small odd jobs done. New plug caps and HT cables fitted,battery earth cable trimmed and mounted, fuel tank sorted (sensor/petcock/fuel cap fitted) and the clutch hose measured up and ready for ordering next week.
Nearly there.

Getting there David.
It will be a close finish who will start up first
i just put my carbs together and also had some holes in my new gaskets where there was nothing in my carbs.
I think there is a difference between european and American carbs and that he gasket packege is universal.

Eric

Ok but any idea on those rubber rings/washers ? They arent regular o-rings as theyre flat with straight sides.The recess that they fit in has nothing in it,no hole,no channel,its not connecting anything.The float bowl gasket covers over the top of it.

I cant close up the carbs until these are sorted. The question is, Do I fork out more money and orderthese things or can I do without them?
Or could I make my own by trimming back some larger rings?How acurate would they need to be? I have NO IDEA as I have NO IDEA what they actually DO!!!!

I think you may have your carb bowls reversed from opposite sides based on the square housing facing you in the picture, maybe?
Check the brass tube that it goes into that tunnel area in the center of the bowl.
Good luck.
David

That looks like where the check valve for an accelerator pump would be if you had pumpers. I wonder if some po got some generic rebuild kits and just put them there not knowing why. I would totally be tempted to ditch them and be happy.

Ok, that was wrong. I looked at the thread about VM24 pumpers and see that the check valv is on the same side as the float valve. On the side in question, there is a large tube sticking down that your carbs do not have. I bet Mikuni used avfairly generic cast that could easily be modified for a variety of carbs, and what you see is the spot for that tube.
Again, I vote for tossing the seal, having a beer, and going on with life.


kzrider.com/forum/3-carburetor/604840-kz...r-pump-clip-question

Ah TexasKZ. Just the sort of advise I need. In fact looking at the Official Kawasaki workshop manual,It does indeed say'Toss the seal,have a beer and go on with life'.I found it in the carburetor section.
Anyway,what you say makes sense,that its some sort of redundant part of the casting.That explains why theres nothing going to or from it. I did have a look at buying the washers and,for 4 of those useless little buggers it would cost euro3,50 each.Plus shipping,Plus tax comes to a grand total of euro27,23!!!!!!! I kid you not.
As I was on the way home from work,I had a McGyver moment and nipped in to one of my favourite shops.. euro 20,00 for a couple of punches.Now I can make hundreds of useless rubber washers. This time next year Ill be a millionaire!