Parts swap from Tourer/Interstate to Interstate -Final update

[Kingbee]

Because of seemingly un-solvable hot idle problems on my Interstate clone Tourer, I picked up a low mileage Interstate to swap all my painted parts, exhaust, suspension, electronics, accessories and chrome with.  
A couple of the hassels are:

"Stinger" is a Tourer, with it's original instruments, so I can't just swap fairings & plug them in.
All the locks have to be swapped from everything, so the un-swapped fork locks will match all the others, only needing 1 key for the whole bike.

So, here we are, ready to go this afternoon.



There just wasn't a lot of time today, but I got all the elctronics off the bars, swapped the adjustable levers (cleaned & lubed), got the pods and air horn removed, removed the windshields, driving lights and painted portion of the fairing removed and swapped the headlight assemblies. The yellow fairing wont' be installed until all the new accessory wiring is completed and the forks, fenders & front wheels are swapped.

Only got 4 hours in today, had to go for a dinner ride.  So, here they are, all tucked away for the night. It's going to get very crowded when the Rune comes back from the dealer after some warranty work.




Oh, and Queenbee just informed me that all the parts have to be out of the dining room before Mothers Day.  Great!

[BF]

Wouldn't it be easier just to paint the new low milage I/S like the Bee instead of swapping all of those parts? 

[Kingbee]

That's a fair question.  I know for a fact that my painter would charge at least $3k to duplicate that paint job again. My labor = FREE

There is so much chrome, and many accessories you can't even get any more, they have to be moved.
The black bike's exhaust has had the piggies cut - that won't do.
My complete Progressive suspension has to be moved.
Stinger has new tires, gotta move 'em
I've got well over $20K invested in Stinger, but it's technically a '97 Tourer with 80K, so what's it worth?  Not that much, for sure......
I'd never dream of selling her, but by moving everything I feel she still lives on, and that nagging, probably very minor problem that nobody can find, will be gone. That problem has never caused the bike to stall or anything, it's just irritating.

This time of year, a dealer might give me $6 - 7K if I'm lucky, after the swap, but I'll end up with a basically new, low mileage Interstate, decked out exactly the way I want it.

Except for the hot idle problem, someone is going to get a great, black bike, meticulously maintained.  Everything else is perfect, and in informal roll-ons with friends, she's slightly stronger.
So this Tourer will come up for sale with:
Interstate carbs with 38 jets
Interstate fairing and trunk
Heated grips
Stereo
Audiovox cruise control
Hondaline CB
Interstate radiator
Interstate pods with grills
Interstate tank and fuel gauge
Temp gauge in dash

Time to start my laundry, and get back to the job.

[PAVALKER]

Wow.... that seems like a project, an interesting one but still a project.

What do you mean by "hot idle" and what have you done to correct it?

Hmmmm, you might want to consider selling the "tourer" as a Tourer and selling the Trunk, Fairing and other I/S Specific stuff seperately, if possible.  Have you seen the prices on Ebay for that stuff?? 

[Kingbee]

The problem takes way too long to explain.  You can read about it here, if you want to.

http://www.valkyrieforum.com/bbs/index.php?topic=2612.0

[Kingbee]

Life got in the way today, but Dfragn came over, and we managed to spend 4 hours on the project.
We removed the fenders, wheels and forks (because of Progressives on Stinger) from the bikes and re-installed them on their new mounts.(painted parts aren't going on the Interstate until all the mechanical work is done)
In swapping the wheels, we didn't want to remove the calipers or pads, but wanted the pads (which didn't need replacing) to match the rotors they broke in with, so we removed the rotors and put them back on the bike they were on originally.  In the PIC, the only visible difference is the black fender now on Stinger.
(I should really take these PICs before I bring the other bikes back in for the night)





With the Rune back from the dealer, things are really crowded at night




Life is going to get in the way tomorrow also, but should have some time in the afternoon.

[Dave Weaver]

Walt,
  You are correct, sir.  Your garage is way too crowded for the project you are taking on.  Plus, if it is raining, you won't be able to push the bikes outside.  I have plenty of room in my garage for that yeller 'Wing until your project is completed.  Good luck on the transfer, and keep us updated.

[Kingbee]

Did a lot of work yesterday, but it doesn't look like it.

Removed the tanks and air boxes, to swap out the quick disconnect fuel line & electric fuel vavle
Swapped out the carb covers - Stinger had billet trim
Drained the cooling systems to swap radiator hose trim
Installed and wired Stebel air horn with relay in right pod area & restored original horn & wiring on the Tourer
Removed engine guards - Stinger had brand new ones
Installed relay controlled accessory fuse panel
Reinstalled air box on the Tourer - Left it off on the Interstate for Audiovox cruise install & Dan Mark fuel valve
Installed PIAA wiring loom
Installed & wired accessory sockets in fairing area
Serviced the starter relay

The fuse panel is hung from wire ties so it can be swung up out of the way to service items behind it



Sockets for XM radio & GPS power supplies.  Love those terminal doublers



Stebel location, with relay right behind it




In the background, is the new Avon Cobra 200 that UPS brought, so gotta polish my spare wheel & get that over to my dealer for install, & shop for misc parts for the Audiovox install & get new bulbs for the Interstate dash while everything is apart

[Kingbee]

Stinger is slowly becoming a "fast Black", slowly.  All the removals of accessories and wiring and reinstalling on the other bike, along with planning better ways the second time and chasing for parts is more time-consuming than originally planned. Then there is the fact that one fairing is analog & one is digital.  Oh, well, I enjoy the challange and wrenching, just wished I'd started in February.




Interstate owners - the fairing is a great place to put the vacuum cannister for the Audiovox cruise control




I FINALLY got smart.  Air box removals were always risky for me because I had so many wires running along the inside of the frame rails.  Not anymore - I have 15 circuits running through on the new Interstate, and NONE of them will interfere with the air box install.




One more tip - If you have an Interstate tank, cut the locking tab off the blue connector for the fuel gauge and wire tie it in place.  That connector won't come apart in use, but when you go to remove the tank it will separate by itself.  When you go to reinstall the tank, it's a one-handed job to just push the connector back together.

All the vacuum plumbing and check valves are also in there for the audiovox install, although the pair valve controller has to be temporarily removed to do the throttle linkage.

Yeah, I know, should cover the intakes, but, by nature, aren't we risk-takers?

[fudgie]

I have garage envy! I wish I had a problem with too many bikes! 

[Mr.BubblesVRCCDS0008]

I have my vac res. and my servo mounted up under the fairing on thr left side. Makes for an easy and clean installation.

[Kingbee]

Do you have any details/photos of your servo install in the fairing?  I haven't done the servo install yet.  Last time I did the Audiovox, the biggest pain was using up all that excess throttle cable length.

[fudgie]

Do you have any details/photos of your servo install in the fairing?  I haven't done the servo install yet.  Last time I did the Audiovox, the biggest pain was using up all that excess throttle cable length.

When I helped J Peebles with his, Ritsema found a small rubber flap in front of the triple tree. Undid part of the fairing and wrapped the unit, to help with vibration, and slid it up in there. Plenty of room. Ran the wires and cable through the flap. Worked good!

[Kingbee]

The cable length worked out perfectly




Now to see if the fairing will clear it.............

[fudgie]

The cable length worked out perfectly




Now to see if the fairing will clear it.............

Thats what we did except for the PVC. Why did you put it up there? No desmog?

[Kingbee]

Nope, no desmog, & it was just too easy to put it up there.

[Kingbee]

But I believe I'm almost half done once the cruise is finished on the new bike, as Stinger is loosing her stripes....

[Kingbee]

While swapping out the exhaust systems, when I got to the right side of Stinger, there it was, in full view - the Centerstand.  It was sooo much easier to remove & reinstall with the right side exhaust removed



Having learned from previous experience that 100 watt headlight bulbs can trash the bulb socket, I replaced them with these high temp, high current units from NAPA



I believe I'm finished with all the electrical work forward of the seat, plus a spare circuit into the fairing and wiring for the volt meter and water temp gauge that are going in the pods.  Everything up there is tested and ready.  Nighty night.

[Kingbee]

Completely disasembling the trunks just to change the locks, although not difficult, is just a double PITA.

It's been 2 weeks since they ran, so to keep the fuel fresh in the jets, I started them today & let 'em run for 30 seconds or so.  An interesting sound without the exhaust systems.

Anyway, the Interstate (Stinger II) is all stripped and ready for it's new wheel wrapped in an Avon Cobra 200, brake pads, a new Hitch Dock hitch, Progressive 440 HDs, and all the painted parts and accessories from it's predecessor.

Sunday, however, we're planning on taking a test ride on the Can Am Spyder, at the factory test ride program that's touring the area. The swap will have to wait another day.

[Kingbee]

Didn't get to do the Spyder today, chores took the forefront.
But managed to get the rest of everything that's being moved, off Stinger.
Then completely disassembled both trunks, swapped the DARN locks and reassembled the trunks again.

Stinger stripped, with the new fairing, tank, fender, front wheel and exhaust installed.

[Kingbee]

Was a good day today.  Swapped the shocks, wired up the car stereo in the "new" saddlebag, wired up the CB and made an antenna mount & antenna from a 1200 Goldwing, installed the bags & trunk & converted the connectors on the trunk wiring to work on the tourer.  This bike is 99.5% done.



OEM CB antennas are virtually impossible to find, but these 1200 Goldwing parts look as close to stock as possible.

[Kingbee]

When I started this project, my deadline was Memorial Day.  To keep up my motivation, I finished the black bike and took it for a spin earlier in the week, and all was well.

The new bumblebee Interstate required a lot more work with all the extra accessories and electronics involved, and the addition of a hitch Dock Hitch.  I couldn't believe the OEM bag rails were ever going to fit again, because of all the added spacers involved for the hitch & hard bags, but they did.  Now, I've seen PICs of bikes with hitches before, and some of them had the bags end up at awful angles, but not this installation, much to my relief.

Took Stinger for a 150 mile shake-down crusie today to scuff in the Cobra 200 and all went well, and the Audiovox cruise worked perfectly.  Now I don't know exactly what it is, especially since I moved all the suspension, brakes etc. between bikes, but I liked the ride of the now black bike, my beloved bumblebee Tourer, better.  Go figure.
Tomorrow is Memorial day, & I think it's going to rain, but at least I finished, and all my bikes are in the garage, instead of being covered up in the driveway.
Next project is the installation of an Audiovox cruise in the Rune - A very different type of installation.

[PatrickDoss]

So the important question is: Did the former Stinger, which is now black, still exhibit the funky problem you were having which prompted all this, or did swapping all the parts over "magically" fix it?  And if it magically fixed the former Stinger, did it break the new one ?

[Kingbee]

That's the best part!  The black former Stinger runs like new again.  It was always meticulously maintained and ran flawlessly except for that nagging hot idle issue that recently cropped up.  It's now gone - I gave it every opportunity to act up again, but it doesn't.  And, much to my relief, the issue didn't transfer to the Interstate.

NOW the problem is, the '97 runs so great, it's going to hard to part with my old friend.

[Garland]

Curiouser and curiouser. Any conjecture as to what caused the original problem? I am glad that everything is working well, but after following your ordeal all this time I need some closure!

[Kingbee]

Well now, that's the conundrum.  Everything is working great, so here it comes...."CLOSURE". Sorry, couldn't help myself   

[Kingbee]

All I had to do was install the CB I got from Pinwall on the Interstate.  Hmmm.  First of all, I had moved my tourer fender with the tail light and additional LEDs set in the lense during the swap.  First glitch.  The CB won't fit where it's supposed to, due to the tail light.  OK, no problem, mounting brackets didn't come with the CB anyway, I'll just make my own and move it further rearward, (HINT to a future problem) to clear the tail light.
So far, so good, I had 1/4" clearance to spare.



Reinstalled the trunk & ran all the leads up to where they should be.  Plugged everything in and NOTHING but an ERR message.  Crap.
I remembered an old thread about the splice block in the Interstate main wiring harness causing all sorts of problems & wrote the author.
He wrote back with the pin outs on the 3 lead connector from the CB, and sure enough, the switched power lead was dead.  He also gave me an idea to put a jumper in place temporarily to bypass the splice block, and the CB came alive!.
Here comes that future problem I mentioned.  After buttoning everything up, the seat wouldn't latch.  Well of course not - by moving the CB rearward 7", the large connector now sat 7" rearward and interfered with the seat!  Double crap.



So now I have a working CB that I can't use yet.  I need like a 10" extension cord to make this work.  I'm not going to splice in an extension in the long cable because there are 13 conductors in there, and they're probably shielded.

Anyone know where I can get an extension cable with these kind of connecters?  I may have to start another thread on this.  

Once this problem is solved, I'll be 100% done.

[Bagger John - #3785]

Cut the center divider out of the rear section of the battery box and mount your CB in there, using a couple pieces of closed-cell foam cut into a wedge shape as a buffer.

Works good; lasts long time. Mine's been operational for the last 8 years in this configuration, and yes...the bike has a taillight. 

[Kingbee]

Thanks john, but that space is already spoken-for.  I really need an extension cable.

[Bagger John - #3785]

Thanks john, but that space is already spoken-for.  I really need an extension cable.

Let me see if I can source those connectors. Probably could have gotten some at the Dayton Hamvention last month...I'll check with some parts suppliers I use.

[Bagger John - #3785]

Found these on Digikey's website:

13p inline DIN plug - CP-1013-ND

13p inline DIN receptacle - CP-1113-ND

There are some shielded lines in the cable assembly - mic (intercom) input being one of them - so the best way to determine what type of cable you'll need is to open the transceiver....take note of which wires have a shield layer wrapped on them...then use a multimeter to trace them back into the connector. This will give you an idea of how many "pairs" in the cable require a shielding wrap, and the correct cable can be procured.

Let me know and I'll look the raw cable up ...



http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=CP-1113-ND



http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=CP-1013-ND

[Kingbee]

Forgot to finish this thread.
I re-located the CB to the battery box, as I couldn't find an extension cord.

Regarding the original problem that started this whole swap, about 1,500 miles later, it re-surfaced on the original bike.
What the heck is with that?

[Wingster]

Hi, can you give any recommendations that you leaned when you attached your horn.

[Smokinjoe-VRCCDS#0005]

You Can't Hide Money

[Kingbee]

Right now, I'd rather have good health.  My injuries from my Sep 19th crash still have me on opiate pain relievers, while I'm completely rebuilding the bike again.

[Smokinjoe-VRCCDS#0005]

Right now, I'd rather have good health.  My injuries from my Sep 19th crash still have me on opiate pain relievers, while I'm completely rebuilding the bike again.

I wish you the best Walt thats a hellofa project .