CSR1000 Project Build

OK,Here we go. My attempt to turn a shagged out old csr into something a bit more sexy and a lot more roadworthy.
History. I got it a few years ago as a non runner for euro200 as a long term project.I got it started and after the haze of blue smoke cleared,I threw a tarp over it and left it out back of the house. I left it a couple of years but that didnt fix it,so I pulled the carbs off, gave them an ultrasonic clean and built a rack for them so I could work on them.
I threw an old tshirt over them and left them for another couple of years but that still didnt seem to sort it out.
So,finally,I thought I better stop farting around and just get on with it.
Part 1.The strip down.

Well ,Im new to this foruming, Ive resized the photos,so Ill try and repost them.

Don't forget to "INSERT" the attached pic and place it in desired location inside the message box before submitting the message.

That's what the blonde is talking about.

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Good Fortune!

OK,Ill try that,
Here are more photos of the stripdown.
Engine out and up onto the worktable. Bloody things weighs a ton.(anybody know how much?)



Layed out,ready for the angle grinder. I took off all the lugs and seat hinges and the weird things on the bottom frame rails under the engine,Dont know what they were for,maybe forward controls or running boards.
I didnt take off the odd tube stump that sticks out from the lefthand side down rail.That had me confused.Ive since learnt that it was some kind of mount for a Kawasaki lock. I wont be needing that so Ill lop it off before I go to the powdercoater.




I bought an aftermarket ducktail to try out and plan to do something with it to give a more Z look but itll need some work.Im thinking of a one piece tail/seat unit.


stripping down the rest of it.

keep them pics coming!

can't wait to see what you transform it into :evil: !


leon

Thanks Leon.Its good to know youve got your eye on this. I'll have many questions.
Now for some engine porn.
Like I mentioned,the bike was firing out a lot of blue smoke when I got it running. One of the tail pipes was very oily.(from cylinders 1 and 2) I pulled the plugs out and did a compression test but it was inconclusive. ( 3 tests,3 different results,both with and without oil).So, time to get the motor out,open it up and see whats what.





Top off

Cams out

Off with his head

Barrels off

Start the clean up and see what we have

Polishing up nicely

Not good.Some damage on the 2rd cylinder.


You can see it again here,Somethings been munching around the edge.

The barrels also had some damage though I didnt get any photos of it.
I know my limits and this is beyond me.It needs professional attention.Rebore,hone,oversize pistons and all the rest. That,ll be off to the tuners then.

Back from the doctors. Wiseco big bore kit (1070cc),new camchain,valves reground and new stem seals and some nice stainless allen bolts .I think thats everything. The oil pump/strainer in the sump needs a clean and the clutch
needs looked at but I think I can manage that myself. Im going to leave it for now though as I want to get the engine cleaned up and painted

.Masking up,getting ready for painting



Here you can see some damage from the chain jumping off the front sproket.Ive heard that this is common on the J motors and I got a retaining clip from Z power to stop it happening again.The riveted repair was already on the bike and though its not very beautiful, Ill leave it for now. Itll be hidden behind the sproket cover anyway and I can change it out later if I want.



Here we go, PJ1 time .It was a real drama to get hold of this stuff,but I had used it years ago (before it was banned)
and had good results.Ive spent hours on this site and others reading everyones opinion on the best engine paint. I decided to go with what I know. PJ1 it is.



Now is that sexy or what?









Unmasked,dried but not cured.Very happy with the results.I just have to be careful with it until its all together and running so it will cure.The side cases,I plan on getting powdercoated as theyll take most of the abuse when its on the road.
So, thats the engine sorted for now. Next the rest of the bike!

the engine looks good!


keep us posted,

leon

So,the engine is sorted,for now, and its time to figure out the rest of it. The frame is stripped,delugged.The wheels and swingarm are bearingless and its all ready for the powdercoaters.
But,
One of the reasons for this build was to make something a bit different. I dont like the cruiser style of the CSR but I didnt want to go for a full on front end/ back end conversion.
Something in the middle.
Then again, a lot of the bikes Ive seen on this site have been pretty amazing.
But theres the cost to think about and a lot of possible engineering headaches.
But if I stick to standard,I end up with pretty much the same bike (a cruiser) with different paint.
(same soup,just reheated!)
Though I need to consider the safety side of things. Messing around with different sizes of forks/swingarms/wheels is going to really alter the geometry of the bike .Hows it going to handle??
Well,Ive been pulling my hair out about which way to go.Ive done a lot of research on the interweb,I know a lot more than I did this time last month.
So, I made up my mind.
Then I changed it.
A few times.
Then I ordered some parts.

Heres how it stands at the moment. Original forks ,swingarm and wheels.


Anyone whos looked into a swingarm swap on this website will recognize the GS1100 Swingarm.
[attachment:2]DSC04444.JPG[/attachment

Though from what Ive read, Fitting in the frame is a simple matter of spacing with a couple of washers. Its going to take a bit more than a couple of washers to fill this. The CSR frame must be wider at the pivot bolt than the other
900/1000 frames. Be aware.



Also The GS1100 should be 1 1/2 to 2 inches (3.5 to 5.0cm) longer than the standard swingarm. Not so with the CSR. Im measuring original swingarm at 46cm (18.1 inch)

and the GS1100 swingarmat 47cm (18.5)


Which is good news as it'll mean I wont lose any height at the back end.Though I will still need to change the shocks as the mounts are different.

UPS man came .

One of the most important things with this build ,for me, is to get the lines right. Ive seen many projects on this site and others,where a lot of work and money has been put into something and when it gets to the final stages and you see the bike altogether, something just dosnt look right, A lot of it is down to personal taste and I never liked the stretched look or the kicked up backend. I remember back in the 80's a lot of 'Streetfighters' had the arse kicked up so high,you could bang the back of your head on them. God knows how they handled.
Anyway,I want to get the proportions right on this thing from the start.
'Mock up' time.




I dont have the room in my workplace to be able to stand back and look at everything, Plus I need the workplace for 'work', so Ive built a table to put the bike on that I can roll out into the corridor.

Now I can get a better view of things.

ZX9r front end, GS1100 swingarm and Im still waiting for a GSXR750/1100 back wheel.Ive got the original CSR wheel in it for now and jacked up to the right height as the GSXR ( more or less).
So far,so good.
Once I get the back wheel on it, Ill get a better idea of things. Exhaust clearence was a big worry with dropping the front end from the CSR's 85cm (33,46 inch) to the ZX9r's 77cm (30.14 inch) but it looks like it might be ok.
Im also not sure about the rear of the subframe.As it sits,the 'Ducktail' I had in mind wont work. It sits too high and the line is wrong, So,either I cut the subframe down and put a loop in it , or I forget about the ;Ducktail' and go with something else. Not sure what to do yet.
Anyway, back wheel first,then well see whats what.