Back In The Day – Page 11 – The ExhaustNotes Blog

ZRX RX: An ExNotes Resurrextion, Part 6

By Joe Gresh

I probably shouldn’t badmouth them because they seem to have the business model sewn up and are industry giants, but Partzilla sucks. I’ve ordered quite a few ZRX parts from them and several things they do annoy me. First, I get CT to order everything because it just works out better. Next, many parts you take the time to look up on their parts diagrams are not priced unless you go through the hassle of signing in to their website. Comparison shopping is difficult. The worst is when the page shows the part as available and in reality they don’t have it. This happened to me with the reed valve gaskets. The site said available (which is not the same thing as in stock) but I’ve been waiting about 3 weeks. CT emailed Partzilla about the situation and got a semi-snarky email in return. Is it better to lose a sale or lose a customer?

I get my Kawasaki parts from Southwest Suzuki Kawasaki in Alamogordo now. It’s actually faster than Partzilla and they give me a little discount if the part is outrageous (like those float needles). I go see Dave or Taylor at Southwest with part numbers I get off the Internet and the stuff is there within a week. Maybe the massive vertical integration of the ‘Zilla monster has reached an evolutionary dead end. I’m done with them, no matter that they’ve bought the first three pages of results on Google.

Rant over.

My Chinese petcock showed up and it looks exactly like the original Kawasaki petcock and fit perfectly. Unfortunately, when I tried to connect the old fuel line it had a pinhole leak right where the line expands from 5/16-inch to 3/8-inch. I don’t know why Kawasaki went with the oddball molded fuel line. A 5/16-inch line will provide plenty of fuel to the 1100cc Kawasaki engine.

This is horrible but there are reasons why it is horrible. First, the OEM Kawasaki fuel line would need to be ordered and I don’t want to wait for it. Second, The original line connects to a plastic T-fitting between the No. 2 and No. 3 carburetors. Knowing my luck with old plastic fittings, I feared that replacing the hose entirely would lead to a broken T-fitting, which would mean pulling those damn carbs again. Then there’s the wait for a new T-fitting. I decided to let sleeping T-fittings lie and added a 3/8-inch to 5/16-inch hose barb adaptor complete with an ugly pipe connection between the two. Then I ran a new 3/8-inch line to the petcock. I mean to fix this mess later on but it works and doesn’t leak.

I gave up on getting the gaskets for the reed valves and made two block-off plates to seal the air intake to the exhaust ports. Then I spun up a little aluminum plug to seal the hole in the airbox where the reeds connected. I didn’t take photos of this part because I was in a hurry to hear the bike run.

I installed the rest of the radiator plumbing and started to fill the Kawasaki radiator with coolant and found the slippery green stuff running out the bottom as fast as I put it in. The front log manifold was pissing coolant, which was odd because I had replaced the four O-rings with new Kawasaki parts. This log manifold is behind the header pipes and not easy to access. Off came the pipe and the O-rings looked like they were deformed a bit.

My mistake was lubing the O-rings on the pipe manifold. This made them too slippery and when the pipe was pushed into position the rings slid out of the pipe O-ring grooves. I gave the rings a through examination and decided to clean all traces of lube from the pipe and O-rings. I shoved the thing back together, reconnected the hoses and it leaked as much as it did last time.

I pulled the log manifold for the third time and cussing up a storm. I tossed the new Kawasaki O-rings and dug some Harbor Freight O-rings out of an assorted kit I bought years ago. I was so frustrated I managed to cross thread one of the bolts that hold the manifold onto the engine block. Back off comes the manifold. For the fourth time. Remember, I’m doing all this behind the header pipes and I can barely get my fingers between the pipes.

I managed to get a tap started into the cross-threaded hole and using the tip of a finger to hold the tap and needle nose pliers to turn it, I ran the tap into the hole and straightened out the cross-threaded bit. Amazingly, the hole holds tension and I got the manifold back in place and the hoses connected. The manifold didn’t leak.

With the radiator full of coolant I started the bike. It smoked quite a bit but after a few minutes the smoke eased off. I had set the idle screws at 1-1/2 turns out but the bike seemed rich. The idle mixture screws are accessible with the carbs on the bike but you need a special, shorty screwdriver to turn them. I made one out of bits and pieces. Make sure you have some sort of identifier so you can count the turns by feel. I used a small screw as my tactile-pointer and reset the screws to 1 turn out.

I tossed the seat on the bike and went for celebratory tacos at the Alomar Diner in Tularosa. The bike ran fair if a little rich. After I ate the tacos the bike wouldn’t start. What with everything having been messed with in the preceding weeks I wasn’t sure where to begin. So I kept cranking. And Cranking. And cranking.

Then I started smelling gas so I held the throttle wide open and cranked some more. The bike started making sounds like it wanted to start. I kept cranking. The Kawasaki sputtered to life stinking of fuel. I rode the bike home and it was running rich. I calculated my fuel mileage as 36 miles to a gallon. The ZRX1100 fuel tank vent was whistling like a teapot on boil and gave a gush of pressure when I opened the gas cap. This led me to believe there was a problem with venting.

Inside the ZRX gas cap is some sort of check valve assembly. It consists of two little red rubber valves and I couldn’t figure out how tank pressure was supposed to vent out. The ZRX has a vacuum operated petcock and with only a little pressure the shutoff diaphragm can be overridden. It’s a fine line. Naturally, removing the source of the problem is easier than making it work as intended so I removed the check valves and the bike whistled no more.

The bike was running much better and if anything was now lean-ish off idle. I did a 200-mile test loop through the mountains and the old ZRX1100 returned 53 miles to a gallon.

The Rex is running pretty well right now. I hate to do it but I’m going to buy four more Kawasaki O-rings for that coolant manifold and try again. Even though they aren’t leaking I don’t trust the Harbor Freight O-rings for longevity. I’ll order a new OEM fuel hose and I might take a stab at installing it. I also want a new fan switch O-ring for the radiator. I’m also going to set the idle mixture screws to 1-1/4 turns to see if it helps the off-idle lean spot, The ZRX stumbles a bit off the start. Once all this is sorted, watch for a ride report on the ZRX1100 in a future ExNotes blog.

See the earlier ZRX stories (and other Resurrection stories) here.

ZRX RX: An ExNotes Resurrextion, Part 5

By Joe Gresh

The pressure of getting the ZRX1100 finished by July has eased off a bit. The Carrizozo Mud Chuckers may not be able to make July’s Laguna Seca races. I may have to go alone, which isn’t a bad thing, or skip the modern bikes and go to the vintage races held a week after. I’m leaning towards the vintage races as I really don’t have much interest in motorcycle road racing and the vintage bikes hold my attention just by existing. That doesn’t mean I’m backing off the ZRX1100 resurrexion project. I’m full speed ahead and will stay on the job until I am able to ride Rex again.

One of the things that worried me on the ZRX was the 24-year-old radiator. Kawasaki makes a quality motorcycle but how long can a radiator last? I found an aftermarket radiator on eBay for only $80 dollars with free shipping. You know how I like a deal. The radiator arrived securely packed and undamaged. It was welded aluminum and the workmanship looks excellent.

Unfortunately, there are a few problems with the fit of the aftermarket radiator. The top mounting ears are slightly too wide apart. When fitted with the original rubber isolator grommet the ears squeeze in as you tighten the bolts. It will need a thicker rubber isolator and that will require a longer spacer and bolt in order to avoid squeezing the rubber flat.

The next issue is the top tabs that hook into the expanded metal radiator bug screen are slightly too low. When the bottom screw holes are lined up the screen misses the top tabs completely; they hook into thin air. I slotted the screw holes to lower the screen on the radiator and it seemed to work although it looked like hell.

After those problems I found the blind holes in the side of the radiator that secure the radiator side covers were not centered correctly. You could get one bolt started or the other, but not both at once. This was fairly critical as the side covers also incorporate the bottom radiator mount and horn mounting bolts. To fix this I will need to fabricate new radiator side supports along with horn mounts. I decided to punt and cleaned up the original radiator and installed it. The aftermarket radiator might see future use but I’m not in the mood to do the fabrication right now.

The new Kawasaki water pump fit perfectly and I was able to install the hard plumbing pipes and hoses. This included the log manifolds located on the front and back of the cylinder block. I ordered a set of silicone hoses that fit fairly well except one hose was missing. Fortunately, it’s the easiest one to get to and it is straight, so I reused the old hose. I can fix it later if it springs a leak.

When I bought the ZRX used all those years ago the previous owner had dropped the bike moving it around. There is a small scuff on the headlight faring and the front brake lever was bent out at an awkward angle. I rode the bike like this for years. I decided that since I had the brakes apart I may as well straighten the lever. A little heat from a propane torch is all you need. Don’t go hog wild or you’ll melt the aluminum.

After closer examination I could see why the old float needles were leaking. There was a ridge worn into one and another had the rubber tip flaking apart. I ordered a new set of four needles for $28 (shipping included) from China but could not get an accurate delivery date. I was getting nervous about our trip so I went down to the local Kawasaki dealer. The dealer had Kawasaki-OEM needles for only $39 each. It killed me but I dropped $156 and bought the four needles.

With new needles in hand I checked the float levels. The range given in my book was 18.5mm ± 2mm from the float bowl flange to the bottom of the float. Mine were all sitting a bit high at 18mm. I readjusted them to 20mm anticipating needle wear and seating. After the carbs were back together I checked the floats on the bench and no fuel leaked out. I hope this status holds. Two days later my needles from China showed up. They look identical to the Kawasaki needles and even came with the tiny wire bail that fits over the float to pull the needle down when the float drops. My $156 needles required reusing the wire bail from the old needles.

I can see why so many ZRX riders convert the original air box to pod-type filters. It’s a challenge getting the carbs back into position. You have to mount both throttle cables and the choke cable, then feed the cables through the frame as you battle to slide the carb assembly between the manifolds and the air box rubbers. It took at least an hour fighting to get the things in. Then, once you feel like you have succeeded, there’s the not-small matter of fitting the springs onto the air box rubber groove. None of this would be difficult if there were access. The two inside boots were out of reach and too crowded for my fingers. I managed to get the springs in place using a couple of screwdrivers and a lot of bad language.

While waiting on parts I tackled the fuel tank. Amazingly the inside of the gas tank was not rusted. It had stinky old yellow muck inside but was otherwise in good condition. This might be due to my diligent addition of fuel stabilizer several times over the course of the ZRX’s long slumber. I rinsed the tank using fresh gas and after 4 flushes the inside was pretty clean.

The fuel filter on the petcock was brittle with age (or fuel stabilizer) and crumbled to the touch. The filter is not sold as a separate part so I bought an entire petcock for less than a few Kawasaki gaskets. Again, from China. I didn’t pay attention to the delivery date and the petcock was promised between June 7^th and July 15^th. This was a huge window, so I bought a rebuild kit and it didn’t show up, either. Panicking, I went to the local dealer and ordered the inner packing and the gas tank O-ring figuring I could at least make something work. As you can see, I’m using a shotgun approach to parts as time grows short.

The petcock rebuild kit showed up a day before the Kawasaki stuff did and I managed to get a petcock assembled. My main issue with this plan is that since there is no interior fuel filter I’ll have to fit an inline filter. This is not as easy as it sounds because the Kawasaki uses a large 3/8” fuel barb and the 3/8” inline filters I’ve found are too large to fit under the carbs or below the petcock. Maybe my new petcock will show up soon and solve the problem for me.

The big holdup now is the gaskets for the reed-valve pollution plumbing located on the valve cover. The law of unintended consequences says that I should have left the reed valves alone when I painted the valve cover. But I didn’t. They tore when I removed the reeds to paint. I ordered the gaskets weeks ago and they have not arrived.

The reed valves allow fresh air to be drawn into the exhaust ports when there is a vacuum pulse at the exhaust port. Kind of like a smog pump without the pump. The reeds connect to a carb-vacuum-actuated valve that is supplied via the air box. I’m guessing this is some sort of backfire control. I can eliminate all this junk and I might do just that but I will need to make a blank plate to replace the reeds and a blob of high heat silicone to replace the gaskets. Then I’ll need to plug the hole in the air box. It would be faster to bolt the junk back on as the bike ran fine with it.

I also installed the new battery and tested the electrical system. I tested the lights and horn and they seemed to work then I bumped the engine over to see if the electric starter still functioned. Maybe in Part 6 this motorcycle will start.

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Life as a Digital Nomad: Part 4 (Panama)

By Mike Huber

Having just left my new home in Nicaragua and boarding a local bus on a 26-hour ride to Panama had me almost second guessing my decision. The bus was full, and the bathroom already looked like a scene out of Poltergeist. Now, all this I was able to tolerate, but what really got my goat was that they had TVs every few rows. You’d think “OK, we’ll watch a few movies to pass the time.” Not on this bus. They had a Kirk Cameron movie (Fireproof) on repeat AND in Spanish. I had never seen this movie and by the 2^nd time it rolled on I was ready to just set up camp inside the destroyed bathroom just to get a reprieve from it.

I eventually fell asleep with the help of some Flor de Caña that I smuggled onto the bus. After what felt like forever the bus came to a stop, and I noticed everyone was getting off. I was still half asleep when I was ushered off the bus. Still bleary eyed I looked at my watch. It was 4:00 a.m. We were at the border of Nicaragua and Costa Rica and the border crossing didn’t open until 7:00 a.m. I was beginning to understand why the bus ride would take 26 hours. After sitting on the concrete for 3 hours the border finally opened, and we were welcomed into Costa Rica.

Once back on the bus my anxiety increased as we all wondered what type of obstacles we’d have to overcome to enter Panama. Entering through the Panama border was less time consuming but again the bus emptied and everyone was guided into a small room with their luggage, where we all had to open each item as dogs systematically sniffed through all the luggage, piece by piece. Then, once back on the bus, we continued the journey to Panama City. Fireproof was probably on its 8th showing.

The further south we traveled the landscape continued to change, as did the neighborhoods. In Nicaragua the houses were in mostly poor condition but by the time we were in Panama they were more like those you’d find in the United States, modern and well maintained. This was due to the Panama Canal which draws in an unreal amount of revenue for the country.

As we pulled into the terminal, I was exhausted and ready to exit the bus. Fireproof was still playing on the TVs overhead and I couldn’t leave fast enough. It was a short taxi ride to the hotel I had picked in downtown Panama City. I quickly learned that in 2012, almost anywhere outside Panama City was difficult to find an affordable place to stay with solid wi-fi to perform my work duties. This was frustrating as I hit wall after wall, all the while residing in a Marriott, which was not what I envisioned life in Panama would be.

After 3 days of continued failed attempts at finding a suitable home, it was time to decide to move on or return to Nicaragua. I honestly think the thought of another 26-hour bus ride back to Nicaragua with Fireproof playing nonstop was the key factor in deciding to move onward. But to where was the question. I was at the end of Central America so this meant I would have to fly to my next destination. Looking at a map the logical choices were Columbia or Ecuador. I left it up to a coin toss to determine which it would be. The coin landed on heads, so Ecuador it was. That day I booked a flight to leave in 3 days.

This decision left me with limited time to tour Panama City. I am not huge on tourist spots but the one place I wanted to see was the Panama Canal. It didn’t feel right to be there without seeing this engineering marvel, and I am glad I did. The canal was extremely impressive, and they had grandstands you could sit in to watch the massive ships pass through the initial two steps of the Miraflores Locks. These two locks manage to raise ships 54 feet higher as they let the water rush in. The ships traveling through the locks must surrender their boats to a Panamanian captain (to include raising Panamanian Flag on their masts). Many boats were extremely large and had very little leeway on either side as they steered through the canal, so the captain piloting the boats must be certified and skilled in navigating the tight canal locks.

The remainder of the days spent in Panama consisted of getting in some short runs along the waterfront and starting the preparation for the next stop in Quito, Ecuador. Research showed that the wi-fi in Quito was fast and reliable. This put me at ease since the pace I was going for was a minimum of one month per country. This pace would allow me enough time to settle and fully absorb the culture instead of just being in a vacation mode. I wanted to be immersed in the culture and was determined to stay in Quito for that minimum length of time. Upon landing in Quito, I instantly knew that a month there wouldn’t be enough and would require me to adjust my schedule yet again.

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Mike Huber Stops By

By Joe Berk

Good buddy Mike Huber rolled through So Cal a few days ago and spent the night at Casa Berkowitz. It was a fun visit.

Mike Huber on the UberMoto. Mike’s current GS is his second one.

I first met Mike on one of the CSC Baja expeditions, and the circumstances of our meeting hit on shared interests (motorcycles and Baja) and a shared background (we are both alums of the Benning School for Boys).

An August 1972 jump school postcard purchased at the Benning School for Boys Post Exchange.

The CSC crew (me and maybe a dozen fellow RX3 riders) had stopped for gasolina on the 200+ mile stretch between Baja’s El Rosario and Guerrero Negro. Cataviña is about 130 miles south of El Rosario, and for a long time it has been the only place to buy fuel on that section of Mexico’s Highway 1. There were no gas stations then; enterprising Mexican capitalists sold it from bottles on the side of the road (capitalism rules, my friends). Today there is a Pemex in Cataviña, but that’s a relatively recent development.

Refueling in Cataviña. That’s good buddy Tuan, an RX3 rider and one of my former students at Cal Poly Pomona.

You can imagine the scene…a dozen bikes crowded around a handful of people selling fuel out of jugs. Or maybe you don’t have to imagine it; just take a look at the photo above. It was a hot day, we’d been on the road a while, and we were two days into a seven-day trip. I looked at the other bikes around me and on one of the motorcycle tailpacks I saw a decal that commands instant and profound respect from anyone who’s been there: The winged parachute emblem showing that the bearer graduated from the US Army Airborne School at Fort Benning, Georgia.

Mike’s jump wings on the back of his first GS. It was this emblem that first alerted to Mike and his background. Mike’s done 19 jumps (5 in jump school and another dozen when he served with the US Army’s 82nd Airborne Division).

When the jump wings fell off, Mike replaced them with an 82nd Airborne Division decal. The “AA” stands for “All American.” I learned that when I asked one of my jump school instructors; he first told me that for us trainees, it stood for “Almost Airborne.” Then he told me the real story.

That’s weird, I thought. I had only known the guys on this ride for a few days, I’d seen all of their bikes, and if any had been adorned with jump wings I would have picked up on it immediately. I was pondering how I had missed that when I looked at the guy standing next to the bike. It was Mike Huber, whom I had not met yet. My next befuddled thoughts were that I thought I had met everyone. Where did this guy come from? Then I looked at the motorcycle. It wasn’t an RX3. It was a BMW GS 1200. The two machines looked enough alike that I had not noticed the difference when Mike worked his way into our herd of turtles at the gas stop in Cataviña. I looked up at Mike again and he was grinning. He knew I was confused and I think he was enjoying my being perplexed.

Mike’s current GS 1200. It’s a stunning motorcycle.

Mike and I hit it off immediately. He stayed with us a couple of nights later in Mulegé (at good buddy Javier’s magnificent Las Casitas Hotel), and we’ve kept in touch ever since. Mike did a guest blog or two for us here on ExNotes, and he became one of our regular writers last year.

When Mike told me he would pass through our neck of the Peoples Republik, I told him we wanted him to stay the night and enjoy a barbequed salmon dinner with us.

And the starboard pannier. Mike gets around, as you know from his blogs here on ExNotes.

We had a great visit. The Tecate cerveza (and later, the Spanish wine) flowed freely. Sue crafted a desert we recently learned about on an olive plantation in Spain (see our most recent blog), and it was awesome.

The post-dinner treat: More vino, and chocolate gelato topped with orange-infused olive oil from the Basilippo plantation in Spain. Olive oil on ice cream sounds strange, but take my word on this: It’s wonderful.

As always, it was great to spend time with my good friend and fellow scribe Mike. The next morning after a good breakfast Mike was in the wind again, headed north toward Ojai, the Bay area, and beyond. You will be able to read about those travels right here, on your favorite motorcycle blog.

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Enjoy the Day

By Joe Berk

It was 50 years ago that I joined the U.S. Army. I went to college on an ROTC scholarship and graduated with a Regular Army commission, the same as the people who graduate from West Point. Three days before graduation, the Army told me my first duty assignment would be staying at Rutgers and getting a master’s degree, all courtesy of Uncle Sugar. Guys I went to high school with were going to Vietnam; the Army sent me to grad school. It didn’t feel right, but it was what it was.

The ROTC scholarship was a sweet ride; grad school was an even better deal. Uncle Sam picked up the entire tab, paid me a housing allowance, and I drew my full pay as a second lieutenant. As I recall, it was something like $436 per month. I couldn’t believe how sweet life was and how I was rolling in dough (grad school was actually easier than undergraduate school). Three of the guys I went to high school with were killed in Vietnam. Several more served over there.

Memorial Day has always been a special day for me, and not just because of what I wrote about above or my time in the Army. I think about the guys I knew and I remember them. You don’t have to have served to do that; all of us should take the day, enjoy it, and think about the people this special day honors: Those who were killed in action fighting America’s wars.

Enjoy the day, my friends.

ZRX RX: An ExNotes Resurrextion, Part 3

By Joe Gresh

Labor rates at motorcycle shops are well over $100 an hour and that fact got me thinking about the value of old motorcycles. Take my 1999 ZRX1100: The basic bike is sound but there are many minor issues that add up to a lot more money than the motorcycle is worth. If you took the bike to a shop, that is.

Fixing a bike yourself means you can take more risks. You can reuse iffy parts that a dealer mechanic cannot. The brake system on the Rex was in sad shape. All the calipers were stuck and the master cylinders were stuck, too. If I worked for a shop as a motorcycle mechanic I’d tell the customer they need all new parts. I couldn’t take the risk of my rebuilt caliper failing or coming back for a leak.

The bores in a brake caliper are not super critical as the sealing is done mostly on the piston walls. Unfortunately, my caliper pistons were not in great shape. I polished them as much as I could and cleaned up the bores. New o-rings and dust seals will hopefully keep them from leaking.

The master cylinder bore is much more critical because it forms the sealing surface for the piston and seals. Luckily the bores on the clutch and both brake caliper master cylinders were in good shape.

The rubber bits for the front and rear master cylinders looked ok-ish to me so I reused those parts. I’m to the point that I prefer old OEM bits to new aftermarket bits if I can get away with them.

The levers have a pressed in dust seal and I didn’t have a tube the correct size for the job so I turned out a short piece of PVC tubing to push the dust boot into place.

I ordered a new clutch master seal kit as I tore the original dust boot dismantling the thing. I also bought a clutch slave kit but the bore was so bad by the time I had it remotely smooth the piston was loose in the bore. I have ordered a new clutch slave cylinder.

All in, there were 18 hydraulic pistons in the ZRX that needed service. A shop mechanic would never re-use the stuff I did. It may come back to haunt me later.

I bought two new, made in Malaysia Continental tires for the Rex as the ones on the bike were made in 2009. The old tire sidewalls had small weather checking. I would have run the old tires if I was just bopping around town but I have a few long trips planned so at $200 for the pair I figured I’d better bite. The Harbor Freight tire changer made the job tolerably easy. Still not as easy as having a shop do it.

The fork seals were leaking so I popped in a new set of fork seals and replaced the fork oil and while I had the front end apart I dropped the lower triple clamp and pumped in some much needed grease to the steering head bearings.

I also bought a new front sprocket and new X-ring chain for the Rex. The chain had a new style master link that worked by pressing the side plate on using small nuts then breaking off the studs that stick out. If it works it will be a good idea, if not I’ll probably break my engine cases when the chain lets go.

If I had taken the ZRX1100 to a shop by this point I would have already exceeded the value of the motorcycle. A shop would need to put in all new brake components to cover their butt. I’m willing to risk my life on shoddy equipment to save money and I’m nowhere near done with the bike or spending money, as you’ll see in future blogs.

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Life as a Digital Nomad: Part II (Exiting the Wheel)

By Mike Huber

It was May 2012, Boston was becoming extremely boring, and the thought it might be time to expand my horizons began to grow inside my head. Still remaining as a “work from home” employee and having traveled throughout most of the United States with not so much as a hiccup in missing calls or people asking “Hey, where are you working from today?” Most wouldn’t expect any type of a response outside “my living room” or “the kitchen table” since that is what everyone was doing and to think an employee was winding up roads in New England on an Italian sport bike or hanging out in Haight Ashbury in a coffee shop while leading a project team call was unthinkable. Now, many will read this and think I wasn’t working and just touring the country while attending a call here and there. While that perspective isn’t totally wrong, it isn’t fully accurate, either. My organization was giving me awards every quarter, to include project manager of the year. While this was all happening, our company was constantly laying people off to the point where morale was extremely low.

Even with my newfound freedom I felt myself being dragged into the depths of depression due to the constant threat of layoffs. It was time to take this working from home to the next level. That being the “what if I don’t have a home” plan. It wasn’t much of a plan, but more of an execution of an idea born over a few beers in a dark Boston bar two years earlier.

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As with everything in life the first step is the scariest, but also the most critical to set the wheels in motion. After thinking this over for a bit the most effective way to ensure I followed through with my plan of setting myself free geographically was to rent out my Boston condo. This was easier than I expected, and had it rented through a management company in under two weeks. June 1^st my new tenant would move in. This was it. I was going to not have a home for at least a year. A timeline was now drawn for me to sell everything I owned and find out where my new “home” would be.

Somehow, I knew that returning to Boston wasn’t going to be in the cards. Having a massive fire sale seemed the best way to clear my life of material possessions that were now just clutter, and there was a lot of clutter to be cleared. With time being short it was an emotionless task to sell, donate, and give away almost everything. Paying for a storage unit for an unknown amount of time seemed pointless.

Once everything I owned was condensed into a small box of keepsakes and my travel backpack it was time to decide where to go. As I looked around the condo (which echoed because it was empty), I was left with the question that I probably should have started with before taking all these drastic actions. Where the Hell am I going to go? This is one of those “I may have screwed up” moments.

Originally the semi sorta kinda plan was to just drive around the United States and spend a month or so in each state and see what became of it. As I was looking at a map figuring out a few first stops on my new journey my phone rang. It was a 617 Boston number and instantly thought it was a spam call. Well, this is one call I am glad I didn’t push to voicemail. It was one of my relatives whom I had gifted a Magic Jack plug a year or so ago. He was calling to catch up and let me know he was had just moved to a house in the jungles of Nicaragua and had internet service that was just as fast as in the USA. My jaw dropped and I threw the map of the United States into the trash can that was already overflowing with trinkets and other items that I felt would never be needed again.

Feeling so lost in the United States (on many levels), a new environment would not only be healthy mentally for me but might propel my work motivation (which was currently nonexistent). Right about this time most of my friends and family were sure I had lost my mind. Going to Nicaragua on a one-way flight for an undetermined amount of time seemed reckless and a sure way to lose my job (some even felt my life would be in jeopardy).

Having previously traveled much of Central America, I knew most of these concerns were unfounded or pulled from a news article where one person had a bad experience. The news never really covers the thousands who traveled to this part of the world and had nothing but wonderful things to say about the people, the culture, and the sights that many will never know. Having grown up in Maine (where for many fear to even venture to Boston) it was incomprehensible for them that I would move to Nicaragua.

As I arrived in Maine, I parked the Ducati in the garage, closed the door, and wondered when I would next see that beautiful machine. Little did I know that it would be a year and a half before I would hear the magical dry clutch clacking again. Later that day I boarded a flight out of Logan Airport. With reality setting in I stared out the window. I was really doing this. Nicaragua was going to be my new home.

The Wayback Machine: Zed’s Not Dead

Our latest Resurrection story about Joe Gresh’s ZRX is not our first big Kawi resurrection story. Going back a few years, we previously ran a 20-blog series on a Z1 Kawasaki. This Wayback Machine piece was the culmination of that story, with a link at the end that will take you to the entire series. Those big Kawis are cool, and the Z1 is unquestionably the coolest of them all.

By Joe Gresh

You may recall from Zed 19 I had to re-soak Zed’s gas tank as 10 days were not enough to dissolve the rust. I drained, dried and reloaded the tank with apple cider vinegar and let it sit for 4 more days. This is what it looked like originally:

The second session really knocked most of the rust out. After rinsing I dumped a large box of baking soda into the tank and added clean rainwater sloshing it as I filled to mix thoroughly. I don’t know the chemical reaction that takes place but the baking soda neutralizes the acid, turning the metal a dull grey, almost white color. This treated metal does not flash rust and I’ve been going 3-4 years on another tank I cleaned like this without rust reappearing. It’s like the metal turns passive and stops reacting to oxygen.

If I wasn’t so hell-bent on riding this bike I think I would flush and cider the tank one more time but it looks good enough and I’ve got to ride! I connected a small hose to my shop vac and played it all over inside the tank. I can hear nothing when I shake the tank so at least there are no big chunks loose inside.

Proving that even the simplest life forms can learn I bought an entire new petcock for $23 rather than the rebuild kit for $8. This is real growth on my part. Usually I buy the kit, mess with it for hours then put it on only to have it leak. Only then will I buy the new one. Kawasaki uses a turnbuckle-type left-hand/right-hand thread on the Z1 petcock. It took about 145 tries to get it to tighten up facing the correct direction.

The new petcock has screens inside the tank and a bowl filter but with 40% of Zed’s tank out of my view-field I can only assume the entire tank is as clean as the places I can see. Inline fuel filters, one for each set of two carbs will hopefully catch any debris still in Zed’s tank.

An update on the Z1 Enterprises regulator/rectifier: It works. The battery charges @ 14.8 volts which is still a tad high but much better than the 17 volts Kawasaki’s setup was doing.

From the top Zed looks pretty well sorted. I took it for a ride and it ran really well for off the bench carb settings. It might be a little rich at idle or it might just be our 6000-foot elevation. I’m not going to tinker with it for now. I’d rather get some miles on the bike.

I don’t know what this bracket is for. Located on the right side down tube near the tach drive, it’d too light for a steering damper mount. Anyway, there’s enough stuff on the bike as is so I’m not going to worry about it.

I took Zed to my secret proving grounds and she ran through all 5 gears smoothly. The bike hit 90 MPH without even trying. I’ll need a better front tire to do any high-speed work. The brakes work ok. When you ride a SMR 510 Husqvarna all other motorcycle brakes seem like crap. After 33 miles there are small oil leaks at the tach drive and countershaft area. Maybe the clutch pushrod seal or sprocket seal is the culprit. That stuff is easy to fix.

The patina on Zed is excessive, bordering on shabby. The bike sat outside for years and paint wise there’s nothing left to polish or wax. The finish is just not there. The pin striping is cracked and missing sections. I’m not sure what to do about that. On the one hand a ratty bike may be less attractive to thieves and old Z1’s are getting fairly expensive. On the other hand it does look pretty bad. I’ve seen my Enduro buddy Mr. French do some amazing work with rattle cans. Maybe I’ll give it a go. The paint can’t look any worse.

That’s it: from Dead to Zed in 20 easy sessions. Don’t worry, this won’t be the last you’ll hear of Zed. I’ll be doing some long trips on this bike, maybe Mexico, maybe ride to a few flat track races. I’ll update the blog if I do any more major work on the bike. The story of Zed’s resurrection may be ending but the story of Zed is just beginning.

And there you have it. If you’d like to run through the gears (i.e., the previous 19 installments of Zed’s Not Dead), you can do so here!

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Life as a Digital Nomad: Part 1 (Testing the Waters)

By Mike Huber

In 2010 the company I worked for gave me my pink slip due to budgetary cuts. I was feeling distraught and lost because I had been working there for 8 years. Fortunately, I had a great director who helped by transferring me from a management position into a project manager slot that would be fully remote.

Remote positions at the time were called working from home. It didn’t take long for me to ask myself a question: What if I didn’t have a home? This mostly was bar talk amongst friends and I didn’t expect the crazy scenarios we discussed to ever become a reality. Well…it seems planting those seeds in my mind was all it took for them to nurture, and then to grow into 13 years of almost nonstop travel.

The first two years were mostly spent learning to excel in my new position as a project manager along with clumsily discovering how to adjust my work/life balance in creative ways. This involved motorcycling throughout New England in between work responsibilities.

Something I learned early is that there are McDonald’s with wi-fi everywhere, and at the time it was one of the better places to stop to respond to emails or for a conference call (this was a life prior to riding a BMW, so I didn’t require Starbucks). I timed my rides to reach these locations 10 minutes prior to conference calls. This allowed me time to set up and prepare for them as needed.

The first day as a remote employee I decided to knock out a ride from Boston to Route 17 in northern Vermont. Route 17 is also known as the “Little Tail of the Dragon.” It was May and I was literally working off my Ducati Monster M1100 as I tore up Vermont. Since it took so long to reach Route 17 it made sense to ride it twice to ensure the long ride was worth it and regain the curve back in my tires. It may have been one of the best days I have ever had working and figured this newfound freedom would provide many opportunities to fill in the gaps that I had been missing by going into a regular office day to day.

Riding all the way to Vermont from Boston on your first day in a new position probably was a bit of overkill. I was missing calls and hadn’t noticed my phone was constantly ringing in my pocket (an easy oversight being so heavily focused on riding). I was in flight formation and setting the pace for a flock of mallards that happened to be flying down the White River, which ran parallel to Route 100. Unbeknownst to me the phone continued ringing as the Ducati’s Termignoni exhaust roared through the Green Mountains while I leaned into corners that followed the river.

Shortly after parting ways with the mallards and crossing back into New Hampshire, I saw some lights behind me. It was a New Hampshire State Trooper. Dammit! I am sure I was speeding, but the question always is how fast. It was fast. As I began talking to the State Trooper to try to minimize the damage, I could now hear my cell phone ringing. I picked it up as the Trooper ran my information. It was my new manager based in Virginia calling to introduce herself and ask if I had noticed that I had missed a call I needed to be on. I stated I was just out getting a coffee (which was 100% true; it’s just that the coffee was 200 miles away). This was probably one of my more challenging multitask scenarios (i.e., signing a speeding ticket while on an introductory call with my manager). To this day I feel I would have been able to get out of that ticket had I not been so distracted by work. Lesson 1 as a remote employee learned.

After that day I knew I should take my work a bit more seriously and slow my pace. I continued to ride, but always ensured I attended every call (which I did over the next 13 years). My work ethic has always been strong, and I didn’t want to compromise this position and what I could possibly do with it by losing my focus. Continuing to merge my work responsibilities with riding was something that I honed to an art form.

Once I was comfortable performing my work one or two days a week off the motorcycle, I thought I would step the adventure up a notch: California. I had relatives in Oakland and there was a Harley rental in San Francisco, a short transit ride away. It made sense to fly there for two weeks and work remotely in a new environment and time zone to see how I would perform.

The test run couldn’t have gone smoother. I was on Pacific Time when my team was on Eastern Time. This ensured that by 1:00 p.m. all my tasks and calls were completed. Having earlier workdays provided much more time to explore San Francisco and the Bay Area. A couple of vacation days in the mix allowed time to rent a Harley in San Francisco and take a 3-day trip to Tahoe and Yosemite. Even though I was on vacation those days I felt obliged to join work calls whenever possible just to stay on top of my projects, while obtaining bonus points from management for doing so on my time off. I felt this made up for my missed meeting when I had first started this position in New Hampshire.

The California trip had solidified my abilities to work from anywhere. On the return flight to Boston my thoughts focused on a farfetched mindset: What if I don’t have a home? It would take a few months of planning and a solid leap of faith. As with all leaps of faith you never know where or how it will end, but I felt sure I could make this dream a reality. What I didn’t realize is how far I would take this and the new experiences my decision would deliver. I turned my life into Ferris Bueller’s Day Off on steroids over the next 13 years.

ZRX RX: An ExNotes Resurrextion, Part 2

By Joe Gresh

This ZRX1100 resurrextion started out kind of leisurely. We don’t like stress at ExhaustNotes.us because we are at peace with our surroundings. ExhaustNotes staff have a firm grasp of our place in the universe and see all matter as insignificant much like we see ourselves. There was no big rush, you know? However, things change in life and the ZRX resurrextion timeline has sped up due to the Mud Chuckers wanting to attend the road races July 7-9 at Laguna Seca in California, now known as Polident Speedway. From my house to Laguna Seca is 1150 miles the fast way and we never take the fast way. We might end up doing 2500 or more miles round trip. Thus, the urgency to get the road burner running as none of my other motorcycles are exactly suited to the job.

The first thing I did to the ZRX was to remove as much bodywork as possible to prevent the odd dropped wrench or spilled brake fluid from damaging Rex’s somewhat pristine original paintwork.

Kawasaki ZRX1100 bits and pieces have been trickling into the shed at Tinfiny Ranch and we will soon see some progress on the abandoned, neglected motorcycle.

Starting with the coolant leak from under the engine, I have determined the water pump or the O-rings on the pipes connecting to the pump were the culprit. Seeing as the pump is 24 years old I sprung for a new pump on eBay. I imagine I could buy just the mechanical seal and rebuild the water pump but I’m getting lazy.

The coolant pipes are slightly rusty so I’ll have to clean them up and give them a shot of paint. The paint on the front down tubes is chipped from road debris so I’ll touch up those areas also.

I also bought some new silicone hoses for the pipes. These hoses live directly behind the exhaust headers and while they seemed flexible and in good condition, they are also 24 years old. A lot of stuff on the Rex is 24 years old, because the bike is 24 years old. Funny, it seems like a new model to me. I can remember buying it only a few years old not a long time ago. Is this how aging works? Does time compress making distant events seem close?

The ZRX1100 comes standard with a ground skimming, low-slung exhaust system. The header pipe collector joins under the engine making my motorcycle lift too tall to fit between the pipe and the ground. Even if the jack fit under the bike you’d have to make some spacer blocks to prevent the pipe from hitting the lift. I went with jack stands on both front frame rails and one stand on a cross pipe behind the engine. With this tripod set up the bike feels pretty stable.

Once jacked up I could remove both wheels for new tires. I also removed the clutch slave cylinder that is leaking and then could access the leaking water pump.

The calipers on the front brakes are stuck. My caliper rebuild kits came in the mail so I’ll have plenty of piston swapping to keep me busy. This is one of the chores I dread.

The chain is pretty much worn out. The rollers are loose on the pins and the thing has 25,000 miles on it. Kawasaki used an endless type chain so I cut it off with a 4-inch abrasive cutting wheel. The rear sprocket looks unworn, which I find amazing, and the front sprocket has just the slightest bit of hooking. Most aftermarket junk won’t last as long as an old, used Kawasaki sprocket. I’ll get a new front sprocket and chain for the bike.

My initial goal with the Kawasaki is to fix the brakes, fork seals and tires. That will upgrade the ZRX to roller status, then I’ll be able to push it outside the shed for a much-needed bath. There is a long way to go to undo the damage 9 years of storage has done to this motorcycle so don’t get ants in your pants. Part 3 to follow, unless I skip to Part 5.