MultiPoint Upgrade projects: Updated 3-24-13

[fordmano]

Just started on my MULTIPOINT Upgrade (swap out) of items.

I just picked up a complete set of Galfer stainless steel front, rear and clutch lines off of EBay for $199.00 and it inlcuded a bottle of Galfer brake fluid. I will be taking pictures as I go. So far I have just put my Valk up on jacks yesterday and I have only pulled the seat, tank and side covers as of yet.

During this project journey I will be,

1) Swaping out Front Brake lines for new Galfer stainless lines
2) Swaping out rear Brake line with new Galfer Stainless line.
3) Swaping out Clutch line with new Galfer stainless line.
4) De-Smogging
5) Install Audiovox cruise control
6) Install rear Progressive 416's air shocks
7) install resivoir and compressor for added storage of onboard air for fill ups and in flight suspension adjustments
jetting my carbs.
9) installing my HID lighting.
10) Installing a couple more sets of LED's tail, stop and turn lights.
11) adding the under trunk rear fender stop light from a standard or tourer.
12) new front tire (Avon)
13) New rear tire (Avon)going back to a M/T for now tracking down some odd handling issues I am still having on my Interstate
14) New head bearings.
15) Install my new set of front Polk Audio speakers.
16) New attempt at installing the mini amps I picked up off of FleaBay


Pictures to come if you would like to follow along , I may have missed a couple of things I will be touching also. Sure do wish I could hook up with some of you Veteran Valk mechanics way out here in Sunny California

[fordmano]

Please feel free to leave any comments or advice/suggestions.


Struggling with attaching these damn pictures.


Finally figured the picture thing out I think?

Up on the jacks, things are well started on the teardown portion as of day before yesterday

[fordmano]

Well all the breather stuff is out of the way and here is where I left off before leaving for work this evening. Pair valves GONE
Still working on Installing the Regular De-Smog kit from RedEye.
Pile of parts I have pulled off so far WOW!!! this is turning out to be a bigger job than I was anticipating.

[fordmano]

Unfortunately I will be going back to Motor Cycle specific tire in the rear for now. These darn odd handling issues need to be tracked down and they were not noticable before going Darkside so this will have to go for now.


These stock rear shock will be replaced with Progressive 416's. so these will be gone soon. My father inlaw had me convinced I needed to have an external reservoir for extra air capacity to properly run airshocks but I have decided to install 416's without anything extra as of yet since I have never seen anyone here mention this extra capacity need, we will se how the 416's work out for me.

[fordmano]

My relay bank for lights and my Stebel air horn needs to be cleaned up so that is on this list also.


This is my location where the Stebel was located, will be making a nicer mounting bracket but it will be located back in this area. That darn stock fuel switch will be replaced with I guess a Pingel.

[fordmano]

Todays updates, 10-09-2010.

This is how things started out. Pare valves and reeds housings all gone.


Then I got Brave and really went to town pulling Stuff out of this California bike.


And here are all the extra parts I gots outs of theres so fars

Whats that about 4-5 pounds of stuff? should be faster now, right? It will be lighter.

[Chillerman]

Let us know how it runs after the desmog.  My Cali bike didn't particularly like being desmogged and it has a slight popping on decel ever since.  I've been chasing down the problem for three years now to no avail.   

[JetDriver]

One of the upgrades you mentioned was HID lighting.  Have you found the lights you're going to use?  I'd be interested in your choice.  PIAA just came out with some HID with the ballast in the headlight shell.

[fordmano]

Well it has been a slow last couple of days, Wife had a nice long list of Honey does to take care of so not much at all done on the Valk.

Did some prep work for the Cruise control got all my vaccum lines cut and now just need to pick up a couple more check valves, preped the control unit set my dip switches pulled the little black jumper out silicone sealed the control panel pulled the black and grey wires out and started getting the mounting bracket ready.  Damn, i wish i stillked in a machine shop or had access to a Mill so I could make a real trick looking mount for the dash control portion of the cruise control.

Ready to swap out the carb jets, uh oh no new jets yet. Thought I had my source but now I have been questioned about exact part numbers? what,?

So does anyone have the exact part number for the proper replacement jets? I am going to start with #38's and #108's but my carb guy is not sure what exact ones I need and since I have not pulled them out yet I can't compare then with what he has.  I found a set of 4 jets for under 6 bucks but I need the part numbers,,, anyone know them?

[fordmano]

I will check on the exact model and manufacturer of the HID lights, I picked them up from a member of another Bike forum that I belong to for $50 ebay had them for $85 and he ordered the wrong ones and did not want to pay for shipping to return them so Lucky me. I think I am going to only install one side and compare them before I get rid of my PIAA bulbs. I will verify and let you know which ones they are I will take better pictures when I get that far on this project since fewer people have done that portion and this early stuff is just another picture of what so many others have done.

[fordmano]

One of the upgrades you mentioned was HID lighting.  Have you found the lights you're going to use?  I'd be interested in your choice.  PIAA just came out with some HID with the ballast in the headlight shell.

Well JetDriver, I think this is part one of the info you were asking about. Here is the Make and model of lights I picked up for a tryout.


Here is a picture of the Ballast, I guess that what it is called. It is just about the size of a pack of cigarettes for comparison.

[John U.]

Fordmano, Sudco has the jets, the 38s are # SD-19006. That's Sudcos number which I'm reading off the bag, the web site shows 019-006. You can look at them here: http://www.sudco.com/keihin_pj.html#26
I don't have a number for the mains but maybe that will give you a reference to go by.
Capparall has them cheaper, I don't have that link or their number.

[fordmano]

Lets get back to upating this thread.

Ok when I got the airbox pulled out I found something that bothered me, not a big problem but it really annoyed me. back in '05 a few weeks after I picked up my FatLady I decided I was not ready to yank the carbs and clean them up myself the bike ran REALLY lean and rough,  I ran it way to often and long on full choke not knowing what I was doing. The bike was actually still under warranty so I took her to the local STEALER and had them check her over and clean up the carbs, HUH! well I figured they were ok and good at what they do so I trusted them blindly bad choice. Here is what I found under the AirBox.

[fordmano]

Jets ordered and on the way, I actually found them the cheapest from www.rockymountainatv.com $44.xx delivered they will be here around next WED. I am starting out with #38's and #105's

I spent a few hours last night installing the carb "O" ring kits from Red Eye, I am not totally sure I needed to do this part but since I had the carbs off better now them have to pull them again later, so here is a few pictures of the tear down and "O" ring swap out. I actually found a few "O" rings that felt a bit on the hard side. It did seem like a I had a couple carbs that had some wet greasy buildup on them so I suspect the fuel rails were leaking a little bit.
freshly out of the bike, man it is a rough road to pull the entire setup from and I/S




There sure is lots of room on the top of that mighty flat 6 when them pesky carb banks are pulled out.

[fordmano]

Now when I say I love my Wife I really mean I LOVE my Wife, she has not complained about this project, I have been using the dinning room table as my primary workbench I did my carb work there last night.






Just about done with this step.

[fordmano]

The wife was even OK with me doing my intake runner porting on the kitchen table. Here are the intakes on the Board to keep them in order while I am cleaning up the inside of the runners.


What a pain it is to clean up the insides of these little intakes, I ended up burning up my dremel motor with this, so I have been using my battery operated drill motor it works but it does take more effort. I will take some pictures of the inside of the runners tomorrow after I finish up with the cleaning up (porting)

[fordmano]

I was just thinking,,, probably a bad thing in my case most of the time.

I know there are some exhaust maker/modifiers that have added a cross over tube to their setups but I was wondering if anyone has added a simple crossover tube on the STOCK I/S exhaust?

I know when this is done to and exhaust system on a car it can make HUGE differences in torque but it is normally done to upgraded or aftermarket systems. Lots of newer cars use this technique to help smooth out a motor and also increase torque.

I wonder if my welding skills are good enough to pop a small hole in each cannister on my I/S and weld in an adapter to attach a tube???

What do any of you think about this idea? please give me some feed back on this question.

Thanks,
Matt

[fordmano]

Well I recieved my Jets from rockymountainatv.com today WOW!!! a day early, and with the $44.xx price tag seems like a good deal to me hopefully I made the correct selection for my needs.

Now to install them.
Here is No jets

With Jets installed.

One with and one without,,,

Only one more to go in this picture.

[fordmano]

Got my carb bowl screws changed out followed most peoples direction and went with Allen head screws, they are a bit easier and they look good too. Just reference for anyone that needs or wants to do this They can be obtained at most hardware stores. I went to orchard supply hardware in my area and picked up all but 4 of them so I had to visit another store for the rest. They are M5 x .8 x 16mm if your looking for them.
Here is what the old Phillips heads looked like.

Here is the new Allen heads,, awe much nicer.
 
Just anothr side note, the next size longer (20mm) will NOT work without extra washers to shim the heads up the threads will bind with the return springs or bottom out too early on the fuel rail side.

[fordmano]

Well I also got started on swapping out my Brake and clutch lilnes with the New Galfer Stainless steel braided lines, they sure look good but they are a pain in the ARSE to actually install especially if your doing it by yourself at least it was a challenge for me. I have heard from others that the front set is an easy swap out well I guess I got a different set than they got. I struggled with attaching the old mounting brackets under the triple tree, not too mention I had to go back to the Hardware store for more nuts and bolts. I will just post up some of the install pics. You can probably figure out what is what from the pictures.


Not real happy with how the Speedomoetr line does not fit snuggly against the brake line since the new brake line is smaller diameter then stock and the clips dont clip on tightley.

I guess I will find soem chrome zip ties and just trim them real close.

[Hoghead]

My wife banned me from doing any mechanicing in the kitchen ever since I put a lawnmower engine in the dishwasher. That was 5 yrs ago and I still dont bring it up.

[fordmano]

you can see how the grommets don't fit snuggly with the new lines.

[fordmano]

My wife banned me from doing any mechanicing in the kitchen ever since I put a lawnmower engine in the dishwasher. That was 5 yrs ago and I still dont bring it up.

Well after 26 years of Marriage if this is the worse I do around the house she is just as lucky as I am...
Kilgore, I know where that is. Is it Kilgore or Jeffereson that has the Oil museum? My fathers side of the family lived there for a few years way back during the oil boom early on in the last century. Nice little towns in that area.

[fordmano]

Well today was a pretty good day for this project, I got my intakes finished up all cleaned up and best of all while I was looking around at my boxes of Valk parts I found something I had forgotten about I will tell more about that when I get to those pictures.
It might look funny but after burning up my demel tool trying to clean up the bores of my intakes I had to revert back to my cordless drill motor. Started out with a stone and some sand paper wheels and just did not like the finish it was leaving so I found some different grades of scotch brite and just used a simple zip tie to keep it from spinning on a steel shaft.



Now for  a couple of pictures from before and after the scotch brite did not get any from prior to any clean up.

[fordmano]

Ok and now for the find of the week,,,, I had purchased these nice shinny little covers for the intake boots and had trouble installing them while on the bike (they were bending and I was not able to figure out how to safely pry them open and then squeeze them back tight on the boots) so I gave up and and when I found them today I thought why not put them on while the intakes are off the bike and I could figure out the best way to squeeze them up over the boots. And now here is what I have to look forward too.


And for those that do not know how they really look,,, here ya go.

Those look good to me.

[fordmano]

Well yesterday I got my Pingel petcock in the mail. It sure is pretty.
My wife almost blew a gasket when she saw the tag on the bottom of the package, it looks like it says $2.00 and she knows it was way more than that is what I paid for it. So just so everyone knows I gave about $84.xx for it with shipping. I found a nice little trick on some things to get a small discount or free shipping. Just do a search from somewhere like GOOGLE and type in "online coupons" wow there are a few of these services and a few of those are actually very good. I got 5% off my Pingel and free shipping on some other parts.


I just had to be a little different and I got the Pingel with FLAMES.

So I also decided to add a little splash of color to it, so I added this little Red vaccum cap figured it would be easier to see under there and maybe easier to get a little traction on it with one finger to turn it on or off.

[fordmano]

Now when I pulled the stocker out I had a bit of trouble with it, I was able to pull and I do mean PULL to get it out and then it looked funny no screen,,, WHAT. yep the screen came loose and was very stuck up in the tube, so with a little patients and a pair of pliars it came out and seemd to be deformed a bit.

I guess it looks normal but not too me since I have never seen one from this bike.

Well luckily with my extra effort to remove the old petcock and screen the pipe and threads look fine for the install, just a little cleanup with a rag and a brush.

Here is the original.

And now the pretty PINGEL.

[fordmano]

The only other thing I got around to getting done today is remove and flush and clean up my overflow tank. Did not remember to take a picture of how dirty it was prior to removing it. I have been running "Engine Ice" in my radiator for the last year or so and it seems to have worked very well, but when I started this project list I noticed that what used to be very clear and a pretty blue has now turned to a very dark and non transparent purple so I guess I will be flushing my radiator also now.


Well I found one picture of the overflow tank prior to removal, you can see how dark the fluid looks and sort of tell how dirty the tank is on the outside.

[fordmano]

Sorry I have not updated anything for the last couple days, I went out Dirt riding with a couple new friends with another forum. Well I took a very painful get off. Damn hitting the dirt at over 30Mph when you over 45y/o and I seem to have compressed everything from the outer edge of my right shoulder down and over to my sternum. Oh Hell I hurt bad. It has been a long time since I wrecked out. Good news is my 2009 Yamaha WR450F is fine, seems to have twisted up the triple trees I will just break the bolts loose and see if they straighten up.

Looks like I will be going to Doctor tomorrow or the next day since I am completly out of pain meds and I really am in the need of some.

[JetDriver]

Sorry to hear that.  I hope for a speedy recovery, even for a 45 yr old.

[sugerbear]

this is an amazing thread. best pics i've seen so far. this should be kept somewhere.

thanks for all your time.

hope you heal fast.

[Spirited-6]

this is an amazing thread. best pics i've seen so far. this should be kept somewhere.

thanks for all your time.

hope you heal fast.

DITTO here ! Healing at "older" years is hard. I once could bounce back the next day, now the next month. 

[fordmano]

Well I gave in and went to the Dr. and they say no broken bones but looks like I have torn up some muscle tissue under and around my right Scapula(shoulder blade) off of work for a week to start but could end up being 4-6 weeks before it is all done so NO wrenching for at least a few days, sorry.

And thanks for the compliments on the thread. And the well wishes.

I will try and get this back on track in a week or so, wife has forbiden me to work on anything for one week.

Damn this hurts a lot even with vicodiene and ADVIL and a beer here and there to help wash them down,,,, I think I am gonna go to Cycle Gear and buy one of them shoulder support systems for riding to help minimize my over movement of this shoulder.

[fordmano]

Well I had the wife drive me over to Harbor Freight and I am the proud owner of one MityVac hand vacuum pump. So with that being said when the wife was not looking I managed to get my rear brake line installed and with the MityVac I was able to get all my brake and clutch lines bleed. Wow why did I wait so long to by one of these MityVacs obviously I can't really test the brakes out yet but I can tell you the feel in the lever has never been so, so , so firm and solid even after bleeding the lines in the past. I think between the new lines fresh fluid and being properly bleed I now have brakes that work as Honda designed them to work.

I will put up the final picks of the lines install a bit later this evening, this is being written from my iPhone and I can't copy the link from photobucket here.

[Bone]

Glad your feeling better. I bought a MityVac 7 or 8 years ago. I too was very pleased with the job I could easily do now. My HD buddies watched what I was doing and then started calling me asking if I would try their front brakes. Two different guys could not get any front brakes. Did both bikes at different times taking just a few minutes each. They had brakes when I finished

[fordmano]

They aren't much to look at but here are the Pictures of the Galfer rear brake line installed.
Took a bit of work to install the clamps to hold the brake line in place.

Here is the rear section at the rear caliper that was a tuff bend, took me a couple times before I was satisfied with the amount of arch. The little clamp I found a clean piece of fuel line and just made an angle slice in it length wise and used a pair of pliers to reshape the clamp a bit.


Not much to see here but this is looking downward onto the line as it crosses the swing arm headed toward the reservoir. that little clamp I used another piece of fuel line to snug up the clamp but getting my big old ham hands in-between the swing arm and the frame section was a miracle.


And here is the reservoir, all cleaned up and pretty. Now to get all those damn chrome covers back on and also install the overflow tank on the other side.

[fordmano]

Well I am finally just about healed up and looks like the Dr. is going to release me to go back to work this next week SO I can get back to working on my Fat Lady again. I already have a few new pictures but I am writing this on my iPhone so I can't attach any photos.

I will say with some help from my wife and one of my sons I have been able to get a few thing somewhat finished up and I will post up the pictures tomorrow when I get on my computer.

Ok so from my list

Brake lines front and rear all done.
Clutch line done.
ReJet carbs and install all new rubber parts in carbs done 
DeSmog done. 
Polish intake runners and install new O-rings done. 
HID lights done. And they look great and are VERY bright. You will love the install pics.
Carb sync, done.   But I will go back thru them after the cruise control is installed.
Pingel petcock done.
Received my Dan Marc electric fuel valve that will go in when I pull the tank back off for the cruise control install.
Front wheel has been pulled off and now I found I need new pads I think I will try the rear brake pad trick since these only lasted 20,000 miles.
I will try and pull the rear wheel tomorrow so I can order my tires for the weekend.

Well that's about it for the updates on the upgrades and my injury.
We will get all this rolling again shortly.

[Sodbuster]

this is an amazing thread. best pics i've seen so far. this should be kept somewhere.

thanks for all your time.

hope you heal fast.

+1 on the pics !! Wish more people would take the time, when doing a project, to do that - pictures are priceless - many, many thanks for your effort !!

take er easy

[Valker]

+Another on the greatness of this thread. Can it be added to ShopTalk?

[fordmano]

Thank you all for the kind and encouraging comments.

So we just got home from ThanksGiving dinner at the inlaws so I figured it was a good time to get all this updated again.

Soooooo pull up a chair and get ready to get going again.