SHE LIVES!!!!!!! Adventures with a new project on a Facebook find

[dpcarson]

I think you're the first person I've read about that reglued the hoses in the airbox. It's never been an issue most have ever bothered with, just turn them back to their respective positions and go with it.

I did it years ago.  I forget what stuff I used, but it was still holding last time I checked.  I figured if Honda paid someone to do it and it wasn't too much trouble, I wasn't going to try to find reasons not to do it.

I had beer left and dinner wasn't ready yet, so I had to have something to do.  You know it got bad if I cleaned the garage too.

[dpcarson]

(well, I did fix the toilet last week, but there is simply no fun at all in that endeavor)

  So did you go back with the stock seat or upgrade it while in the process. hopefully the day long is not necessary.

When I bought the house, the master bath was entirely Women's Pink.  It was nicely upgraded and I don't waste money, so it has stayed that way.  The pink seat in there is pretty new (but I generally prefer to only use a small night light in there anyway).  

What I do like is I still have the original 3 gallon American Standard potties.  

LOL  Since it is the older AS high capacity model I am guessing it already has some chrome bling on it.

[Jess from VA]

(well, I did fix the toilet last week, but there is simply no fun at all in that endeavor)

 So did you go back with the stock seat or upgrade it while in the process. hopefully the day long is not necessary.

When I bought the house, the master bath was entirely Women's Pink.  It was nicely upgraded and I don't waste money, so it has stayed that way.  The pink seat in there is pretty new (but I generally prefer to only use a small night light in there anyway).  

What I do like is I still have the original 3 gallon American Standard potties.  

LOL  Since it is the older AS high capacity model I am guessing it already has some chrome bling on it.

You bet, but did you ever notice that plumbing supply is now virtually all chrome covered plastic??  If you go around trying to find real metal chrome, they think you are nutty (or old, the white whiskers and bald head are a dead giveaway).

[DK]

Cool adapter.

I'd like to have one & also a 1/4 - 3/8.

What parts store?

Is it branded?

Never saw a tool I didn't like.

Dan

[Novavalker]

While you have her all apart nows the time to consider installing a cruise control.

http://www.murphskits.com/product_info.php?cPath=25&products_id=422

I installed one last winter. Well worth the it for those long rides.

[Woton]

We don't live that far apart.  Would you adopt me, or at least move into the house next door?

Seriously, be careful in the weather tomorrow...  I look forward to an NC meet-up one day soon to see the fruits of your labors.

[dpcarson]

It came from Advance Auto Dan.  They did have a 3/8 - 1/4 adapter also, but I rarely use anything with 1/4 drive so no real need for that.

Cool adapter.

I'd like to have one & also a 1/4 - 3/8.

What parts store?

Is it branded?

Never saw a tool I didn't like.

Dan

[dpcarson]

Damnit Nova!!!!  Why did you have to show me that!!!!  However, since I have never even heard the girl's heart beat before, I have told myself repeatedly that no more money will be spent until she is breathing.  Then if I have to drop the engine again to do the other stuff then fine.  But unfortunately, it is not like she was running last week and I just have to fix something.  I REALLY want to hear her run before I do start dumping money on anything else new.  Then, well, all bets are off.  However....... I am planning to pull the carb on my standard and de-smog it when I am done with this one.  Might have to put that cruise control on her too!

While you have her all apart nows the time to consider installing a cruise control.

http://www.murphskits.com/product_info.php?cPath=25&products_id=422

I installed one last winter. Well worth the it for those long rides.

[dpcarson]

We don't live that far apart.  Would you adopt me, or at least move into the house next door?

Seriously, be careful in the weather tomorrow...  I look forward to an NC meet-up one day soon to see the fruits of your labors.

Woton, I got the private message.  I pass through there a few times each year.  Like to run to Asheville or Maggie Valley at least once a year.  The cracker barrel there is a regular stop.  We need to get together when I am passing through.  Or maybe ride over to Greensboro area for a beer.

And.... you wouldn't want me to adopt you.  I spend all my money on toys and projects and forget to feed the kids some nights.

[Jess from VA]

Lots of bike work (other than big mount/axle bolts) is easier, less prone to scratching, gives longer ratchet throws, and fits into tight places better in quarter inch.  Quarter inch is the only way to go on the header bolts/nuts.  Only thing I've found hard to locate is quarter inch drive metric allen sockets (Snap-on and such are dang expensive).  

And it gives you an excuse to buy a whole new set of tools.  

[dpcarson]

Well...... The tank is now a setback.  Got knocked off the bench.



However, this project convinced me to go get me a new tool box/workbench that was probably way overdue



And.....the good thing is, the wife is starting to get excited so the budget on this tank (and toolbox that was bought while she was out of town  ) hopefully will not be a big issue!

[dpcarson]

K, so not a whole lot of new updates as far as progress goes, since parts delays have been the bulk of my last week.  I got all of the de-smog done with the removal of the ca smog crap off the bike.



And the dowels finally showed up from the parts site so I was ready to put the clutch cover back on.  I got the sealant on the engine and then got the gasket positioned...



and was then able to get the clutch cover coated with sealant and get the clutch cover in place and torqued down.





I actually did not rebuild the clutch slave while I was in the process but just cleaned it up really well and got it all back in place and got it re-mounted.



And while I was in the process it was recommended by a couple of guys to go ahead an break open the alternator and check out the brushes and clean the alternator up well, so I tore it down and cleaned it up as much as I could and checked the brushes.





I had already ordered new brushes, and what I found when the new ones arrived is that very little of the brushes appeared to be worn.  The new brushes were almost the same size as the ones currently in the alternator. So I left it alone.  I just cleaned it up good.  I did however break apart one of the rubber dampers when I was removing the alternator from the engine so I did replace all of them before reinstalling the alternator.



I then finished up mounting the alternator and connecting the wires and connections.





At this point I had moved the engine back into place and started getting everything connected to mount the engine.



a little moly on the shaft



Ready to go back into place.



One thing I did decide though, and maybe this comes from boats, I hate any pocket in metal that can hold water and let any corrosion start.  When removing the reed valves that leaves the holes that can hold water



So, in order to try to eliminate that I ordered some more chrome flange bolts and used them with a little thread lock to fill these holes and keep then from accumulating any dirt or water.  Probably completely un-necessary but just looked like it needed to be done. 



Then I had to tackle this little rubber boot sob



Which of course I tore and now have to wait on another one before I can move forward.  So, I am in waiting mode, and come home for lunch today and find the tank laying on the garage floor upside down.  It had fallen off the short bench I had it one and dented it and scratched the crap out of it.  Damn that was an expensive lesson.  Estimate from a body shop is 300 – 500.  I priced out the paint alone and the combination of primer, base, clear, activator, and reducer was going to cost me almost 150 by itself, and that is without the dent repair.  So..... I am dropping it off on Friday.







So..... Now I am in a holding pattern until the new boot shows up (hopefully tomorrow or Friday) and then the bike shop said we will have about a one week turn around on the tank.  Hopefully I can get the engine back in and wired up and ready to go this weekend, and even if I have to move the tank from the Standard over to the IS to get it fired up this weekend, I really really want to hear to girl growl before the weekend is over! 

[Smokinjoe-VRCCDS#0005]

Well...... The tank is now a setback.  Got knocked off the bench.



However, this project convinced me to go get me a new tool box/workbench that was probably way overdue



And.....the good thing is, the wife is starting to get excited so the budget on this tank (and toolbox that was bought while she was out of town  ) hopefully will not be a big issue!

Check with Wolf he is a Matco dealer and has some badass toolboxs for sale now.

[Ghost]

What a great report, i will save this in my files for and if i ever need it. Nice Job. 

[dpcarson]

I wish.  No way I could get that in a Matco for anywhere near 300 bucks, which is what I  found this for online at Homedepot.  21 gauge steel, 1000 lb casters, 75 lb drawer slides, and 1" wood top for 299.  Couldn't find a better deal out there anywhere. 

[Jess from VA]

Thanks again Mr. Carson. 

I am learning to to get some hot buttered popcorn before opening your posts. 

Better than anything on TV (and no annoying commercials).

Having the wife happy and smiling (good picture) is always the best time to spend a little money on the man-cave.

Remember, in a pinch, she can always store some shoes in the bottom drawer of that new tool chest (which then makes it a Joint Use purchase).   

Sorry about the tank.  Whenever I have these parts off my bikes, they always go on carpet pieces on the floor.  They cannot fall anywhere .. only be tripped over.     

[dpcarson]

Thanks Jess.  The additional delay is the most annoying thing.  It's only money right?

I can't wait to get the final chapter in place of this story and finish it up with a video of the girl being resuscitated and my inaugural ride on her.

[dpcarson]

Holy Crap you can't make up stupidity like this.  Well I had a meeting this morning in Raleigh so I took my tank with me to the body shop up there to get the repairs and repaint done on the tank.  I put it in the car and then thought, I need to grab that key to make sure they can open the tank and pull the cap in order to repaint.  This is not non-typical for me since the normal me would have forgotten all about the key and had to drive it back up there later.  So I felt proud of myself all day.

Thank I got home and the mailman had dropped the new shaft boot!   
So I decide it is time to start working on the bike!!!!!!  YEEE HAAAA  I will have it running by the end of the weekend!!!!!!! 

..................................................................

Where is that key?

[Jess from VA]

You only have one key?  (I'm sure you know this but...... one key is never a good plan)  

The tank guys could lose it as well.  Call them up and ask them to get some copies for you (and mail you one?).

[dpcarson]

I only got one key with the bike, and since all I have done is work on it so far trying to get it running, I haven't worried about getting another key yet.  Tank should be ready by end of next week, so I guess I will just sit here and be patient again............  Or get creative with my wiring.

[fordmano]

Great thread, hadn't seen it till tonight.

Thanks for sharing. Like most around here you are way more detailed than I am....

[dpcarson]

Well of course, I had some free time drinking my coffee at work yesterday (remember, this is the way I wound up with this project in the first place)  and was reading the threads about the digital carb sync tool.

So...... after a lot of reading I finally broke down and ordered the project kit from Tom to get started.  Looks like I will now be able to finish up my project with a cool digital carb sync to make sure the girl runs like an Ethiopian track star!!!!

[dpcarson]

Well, I thought tonight was the night........  Close but no cigar.

Well lets backtrack.  Last update and I had just gone three rounds with that damn drive boot, and I am not sure who lost but, I wound up stopping work to order a new boot.  OK< well new boot finally arrived and I decided to use a ratchet strap to clamp down the rear seat as low as possible to move the swingarm enough to get the boot on, and IT WORKED!





So, now with that boot on and the alternator on, it is time to slid the engine back in place.



When I went to put the frame bolts back in though I noticed that they had a lot of rust on them, so I took a quick moment to clean them up with a brass brush on a drill.  This cleaned up the threads quite a bit and made them much easier to go in. 







So now I got the engine back in place and all of the frame bolts and hangar bolts in, and remembered to put them all in loosely so I could get them all started and go back and tighten them up later after I am sure everything is fitted up.





So now that the frame is back in place and the engine is hanging from the frame it is time to mount up the exhaust.  So I crawl under  the bike and start to dig out the old gaskets and at the same time notice that the mounting studs for the exhaust are corroded and could use a little bit of cleaning up also to keep them from seizing in the future.







And then I checked out the mounting areas for the exhaust and decided to also clean up all the mounting areas with the brass brush on the drill and clean up those areas to again try to stop any corrosion that might be showing up.







Then it was time to break out the old flexi extension to mount up the exhaust.



So, I got everything cleaned up and mounted up the right side and then was mounting up the left side and then......... pop.  DAMN  snapped the exhaust mounting stud.  WTH.  Grab the book and HOLY CRAP.  Only 7 lb/lbs?



Well, 7 ft/lbs explains it.  Definitely should read the manual first.



So, the preparation of the next parts list begins.

So next we got the radiator mounted up



And the coils







Time to start cleaning up the intakes and replacing the intake o-rings.



they were a little dirty and some corrosion



So I figured while they were off and I was replacing the O-rings I might as well take out the steel wool and clean up the lower mating surfaces.  They polished up real nice



So with everything cleaned up nicely it is time to fit it up.  Maybe it is the boat work or the carpentry work I enjoy but I prefer to fit everything up first for a trial run.





So, everything fitted up.  Then I decided that I didn't like the hole with the broken bolt that I had drilled off and tapped since it would be a different size and decided to go ahead and cut the spot welded nut off the back to I could put another nut on and use the same original size bolt.  % minutes with a dremel took it right off.  I will probably just use a regular lock nut from this point on instead of welding another not on the back.



So.  All fitted up!!!!  Everything  fitting perfect!!!  Oh crap.  Did I remember to do a final tighten and torque on all the engine mounting bolts?  Nope!

So, pull it all back out and tighten and torque all of the mounting bolts and frame bolts and then put it all back together again.  Holy cow what a time consuming, and beer consuming screw up.

So!  Finally!!  Everything fitted up and bolted into place.  Carbs in!  Intakes in and seated!  Everything tighted up!  Whew.  Finally get to start moving forward as far as I can anyway without the tank or key.  LOL.  Does anybody think it is that easy.  Look at this picture and tell me what is wrong here.



Anybody recognize that little sob right there that is smiling at me from the stool?



crap!!

Well, time to re-assemble everything AGAIN, so I can put that stupid little plastic thing back in.  Holy crap what a pain in the but that little piece of plastic is.  By this point, I am wondering if maybe I should start blaming this on the extra beer that the first re-assembly required.

So..... finally back together and with the plastic shield.



Now for the airbox.  I stretched out.  I did my yoga.  I practiced meditation.  I did my breathing exercises, and then we got kinky with some bondage!



Not too bad at all.  That little plastic shield was much more a PITA than the airbox.  So all mounted up, and pretty much at a standstill until the tank is ready.





So, now here we are.  Tank should be ready this week, so I am again in a holding pattern waiting on my new small batch of parts  to replace what I have either lost or broken.  It has already been quite an adventure and I am feeling much better about tackling this task, Now I am just ready to finish it up and put the girl on the road!  I can't wait to hear the old girl roar to life!!!  Not much longer now!!

[..]

My breath is bated with anticipation of the roar. 

[The emperor has no clothes]

  When I saw the first pic without the plastic air dam I thought OH crap he's going to forget it. You are making good progress, good to see the updates.

[dpcarson]

Just got the email that my tank is ready!!!!  Lets see if I can get it home and on without dropping it!

[KY,Dave (AKA Misunderstood)]

Been following the progress and enjoying every minute. 

[DK]

Lots of bike work (other than big mount/axle bolts) is easier, less prone to scratching, gives longer ratchet throws, and fits into tight places better in quarter inch.  Quarter inch is the only way to go on the header bolts/nuts.  Only thing I've found hard to locate is quarter inch drive metric allen sockets (Snap-on and such are dang expensive).  

And it gives you an excuse to buy a whole new set of tools.  

I got a nice set of 1/4 metric allen sockets from Sears a couple of months ago. They were contained is a set of both metric & SAE Allen, Torx, & various security bits - 40 or 50 pieces for about 30 bucks.

Sears is having trouble making payroll & they are frequently putting tools on sale at give away prices. Their tools are still good quality except for ratchets. They have a new line of non craftsman smooth finish tools without warranty that I'm liking better than their good stuff & it's cheap, really cheap. 

I try to make myself  use 1/4" sockets wherever possible. I grew up on a cotton farm where 1/2 & 3/4 were the standard. We even used 1" with 4' breaker bars on the dozers & cotton picker wheel hubs, track rollers, etc. The 3/8 sockets seemed miniature and 1/4 sockets were a curiosity used only by the guys who worked on fuel injectors.

That was a long time ago, but I still tend to over tighten and using 1/4" greatly helps with the problem. Still, I've become quite skilled in the heartbreaking art of removing twisted off studs.

DP, i got both sizes of the socket adapters from Advance. Thanks for the info.

Dan

[Gryphon Rider]

Dpcarson, if you haven't already, get your little inspection mirror and have a look at the back of the six rubber air cleaner tubes, where they connect to the carburetors.  They can look good on the outside, but not properly connected in the back, where you can't normally see.

[dpcarson]

Thanks for the heads up. I had read about that in other threads already and went to great detail making sure they were all fully seated. I appreciate you looking out for me.

[dpcarson]

HOLY CRAP look at this tank!!!!!!!



I was seriously stoked when I picked up the tank today.  This think was like a black mirror.



So I got home and of course was so stoked to finally have the tank back and be ready to hopefully find some fire in the old girl, I didn't take any pictures of the re-assembly process of the tank, petcock,   However, I did break a choke slide and had to order a new one of those.  I am also still waiting on  a few more parts and I am not able to ride until those parts are replaced, however I can at least get the spark!!



So I was excited to get everything back together, get the tank cap on, get the engine filled with oil, get the coolant in the radiator.  Ok, back to the box that I bought home with the tank for the key, where is the key.  Where is the damn key!!!!  CRAP!!!!!!!  Well, I now get to drive back to Raleigh.

OK, home again with the key.  While I was gone I did get to put the battery on the charger and make sure it had a full charge.  Tank on, vacuum tube hooked up, put a little gas in the tank, petcock on reserve,  Exhaust back on temporarily.....

And then!

First fire!

And.... Blew a freeze plug out.  So, at least that is something I can run to the auto parts store to get.

Running!

WOW!!!  So happy right now.  Still a few more parts to come in to finalize everything, but I am feeling like the big work is finally done.  Final count as of right now, with all of the additional parts it took to get it running and get everything in running order anyway puts me at just under $1400. (that does not include repairing the tank damage since that was all on me).  I still need tires, new windshield, and possibly a new battery, but maybe I can trade in some of these leftover parts for partial credit?

 

It is supposed to be a beautiful day Sunday, so I may even take her out for a test run while still missing a few things just to check her out a little, but by next weekend!!!!!!   She should be ready to stretch her legs.  Almost there!!!

[..]

Jolly well done sir.

You gave me a BIG smile 

[Jess from VA]

That's great!  

You didn't use the choke did you?  (mine would start the same way with no choke, poorly)

[dpcarson]

That great! 

You didn't use the choke did you?  (mine would start the same way with no choke, poorly)

Well, I would have...... If I had not broken the choke lever first.   

[Jess from VA]

That great! 

You didn't use the choke did you?  (mine would start the same way with no choke, poorly)

Well, I would have...... If I had not broken the choke lever first.   

You're pretty handy, look up John Schmidt's simple choke lever solution. I tried and can't find it (it's been reposted several times here).  Gets rid of the handlebar switch and cable (with a simple pivot lever on the engine).

Maybe he will chime in. (or message him)

[dpcarson]

Thanks Jess.  I will check that out.  Already have the new switch on the way, but alway open to other options.  As I start cleaning up the tools laying all around the shop and on the rolling tray I will probably find a lot of those other parts I wound up missing.  Might have some new and used parts to hit the market soon!

[dpcarson]

Beautiful weather today!  Time to put the girl on the road for a test run!!





Rolled her out and did some final tweaking.  Still a little skip to her step which I am figuring is a combo of needing a carb sync, and missing one exhaust stud.

Put about 100 miles on her today.  Little wobble in the front tire.  Little skip in the step at low rpm's.  Not quite as smooth as my standard, but I know it needs syncing.  However, I am amazing at the handling of the IS compared to the standard.  This thing is amazingly nimble.  I thought the standard was good, but the IS beats it in the handling and maneuvering department hands down.  I was surprised.  It was also nice to have tunes.  Never had that on a bike before.  Tomorrow I have to connect the horn somewhere, and take it for an inspection so I can get it registered.  Glad I didn't get stopped today since I had to switch my tags from the standard over to the IS project to try it out.  I will say, it is a fantastic ride.  The little bit of skip drives me crazy but my wife did not even notice it.  Also, the exhaust turn outs definitely change the sound.  

I owe many of you here deep gratitude for giving me the feedback and advice (and confidence) to tackle this job and get the girl running again.  I was not at all confident that I could do it, but........ Here she sits.  I bought the kit and parts to build one of the digital sync gauges so that will be my next project, that way hopefully I can get the carbs synced up and get her running smooth as silk.  Can't wait for a registration tomorrow!!  Then she will be legal, even if there are a couple more parts to install as soon as they get here.  

[Hook#3287]

What a great story 

And the end product speaks for herself, but I'll say it any ways.

She's Beautiful!

[The emperor has no clothes]

Congratulations, you did a fine job bringing her back to life And I agree she is beautiful even if it's plain black   

[Jess from VA]

Congratulations DP.  

Holy crap does that paint look good!

Interesting you have a Corbin trunk rest.

I have never seen those Honda wings mounted on the pods before (seen them for sale for years) (always looked like I would hit them with my calves on the Hwy pegs)

Music is great, and I won't ride without it, for long.

Swapping plates on bikes.... wow, no one ever did that before.  

Now don't tell us you're selling it.  That baby is prime for a supervalk conversion. You already have a std, so maybe that would be sort of redundant.  I like the IS too.  I have two, one normal and one permanent supervalk solo (which I greatly prefer)(both black and chrome, of course).  Some wives prefer the additional unrestricted room available on a std/tourer pillion, but the IS backseat has wraparound comfort and music.

Just sell the training wheels and call it good.  

PS, with all that work you did, did you check the valves?  (most people don't find much, and if they do, one or too are a tad loose, and I've never heard of one too tight... which is not good).  That would not cause the skip.  Even with everything clean and new, a big dose of techron or B12 might be helpful.