Grotty Hornet

[Tim..]

Yes! The project lives

Best get some zinc on that bare steel now
____________________
Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[MarkJ]

I didn't do much to the Hornet for the past month, I was busy getting the Sprint ready for the TT. Now that's over I've been working on the bike again. Unfortunately I didn't get many pictures as I wanted to crack on.

I've pretty much sorted the loom now, got the clocks plugged in, done both switchgears, throttle and choke cables. I've plumbed in all the hoses which meant next on the list was...

The radiator. Paint was flaking from the sides and it was loppy.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01019.jpg
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01020.jpg

Gave it a clean and stripped the bits for painting. I didn't want to do anything with the fins as they looked ok and figured any paint applied would just clog them up.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01021.jpg

Painted
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01028.jpg

I then wired up the track bike's battery as I need to buy a new one for the Hornet. Note the rubber glove to protect the positive terminal from shorting out.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01022.jpg

Power!
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01026.jpg

I then fitted a new oil filter to the cooler unit, then filled the bike up with oil and water.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01027.jpg

But unfortunately, the oil cooler was leaking fluid
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01029.jpg

...because the seal was clogged with the remnants of old coolant
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01033.jpg
Luckily I have a spare old CBR600 engine that I bought for its engine casings years ago, when I had a CBR600 track bike. Luckily the oil cooler is the same shape so I stole the gasket from that. After fitting there were no more leaks

Sanded the radiator guards just to make them look a bit tidier. Will do a better job at a later date.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01035.jpg

And this is what it looks like now:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01036.jpg
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01037.jpg

After getting the engine water tight I turned the engine over with the coils disconnected to pump the oil around the pretty much dry engine until I got the oil light to go out. I'm going to get some petrol for it tomorrow and fingers crossed it'll fire up.

Things left to do:
Fit drive chain
Footrests
Clean rear brake pistons
Fit rear brake
Clean front brake pistons
Fit front brake
Buy and fit new front discs
Possibly buy and fit new headlight
Fit exhaust
Fit airbox
Buy & fit battery
MOT

After it's MOTd I'll get the grubby bolts zinc coated and give it a new paint job.

[MarkJ]

It runs Managed to piss fuel everywhere though as I'd left all the float bowl drain screws undone

Sounds like it's run on a mix of petrol and bubble bath with no downpipes

[Fladdem]

VID! VID! VID! VID! VID! VID! VID! VID! VID! VID! VID! VID!

And so on and so forth....
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.

[MarkJ]

clicky

People using headphones might want to turn the volume down first

[Super Manx]

About time strokey!

[MarkJ]

Been working on it tonight, noticed a tiny drop of water on the oil cooler. Hoping it's just condensation or something, if not I'm tempted to just smear the seal with my gasket paste.

The past few days I managed to get the airbox on. What an absolute fucker it was, too.

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01041.jpg

Also put the chain and front sprocket on. Had to take the swingarm off to slide it on
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01042.jpg

Then tighten everything up again
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01043.jpg

And also did a trial fit of the downpipes, held on with a couple of bolts.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01046.jpg

Need to buy myself a headlight now. Anyone know the diameter of a standard Hornet headlight?

[Llama-Farmer]

7" iirc for the early Hornets, 98-01.

01-onwards came with a more rounded, better looking headlight but with different bulbs and perhaps requiring different wiring loom.
____________________
Current Bike: 1999 Honda CB600 FX Hornet
Next Bike: I want a CBR-RR. And I want an F800 GS-A. And a VFR 800. Can I have all 3?
Dream Bikes: Honda VFR750R RC30, Honda NSR500, Ducati 996 R

[MarkJ]

Cheers

[Admiralbutthe...]

Ive seen the girly bone arms in that video somewhere before...

Simba? is that you?

[woodyeee]

When I first saw the pics I thought thats gone to far! But fair play its coming on nicely. By the time it's finished it will be worth the £1200 you originally paid for it in 2006!

[TUG]

[MarkJ]

[TUG]

[MarkJ]

Not updated this for two months but I have been working on it in the time. Haven't taken loads of pictures as I've been busy getting on with it.

Rebuilt the rear caliper
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01048.jpg

Then fitted it
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01049.jpg

The alarm was acting up, wouldn't disarm even when you put the fob next to the alarm, so that was removed. Left a nice handy space.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01057.jpg

Begone vile beast!
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01058.jpg

Bought a new headlight, tested it by holding the wires together. Looks better than the dominator headlights.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01060.jpg

Fitted the speedo cable and front sprocket cover
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01068.jpg
Yes I know the lever and linkage are rusty as fuck.

And rear disc
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01069.jpg

Headlight switched off. Which then had the wires neatly soldered and shrink wrapped.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01070.jpg

Nice and neat, rather than horrible bullet connectors
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01071.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01072.jpg

I bought some new front calipers for the grand total of £12, which then got a rebuild. They actually didn't need it but was nice for peace of mind.

Pistons popped out with the help of compressed air.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01062.jpg

I've found feeler gauges are the easiest way to get seals out.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01063.jpg

All cleaned up
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01064.jpg

You can see the seals taper out. Most flared out part towards the pads.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01065.jpg

Red rubber grease to keep the seals supple
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01066.jpg

And in they go
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01067.jpg


Homeward straight now. Decided to do a test fit of the bodywork and exhaust. Paint needs retouching, but I actually really like how the yellow contrasts with the black. Much better than the silver and grey it used to be before. Might just paint it the same colour again. Was going to do orange but orange Hornets have been done to death.

The pictures without the flash show the colour better, but are blurry. With the flash the image is sharper but looks orangey.
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01080.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01078.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01077.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01073.jpg

[blueglue]

First time reader to this post.

good job as i was worried when i got the 'old thread alert' that you may have given up.

[Doomsnite]

Looking good mate. Have a yellow hornet myself and considering going black on the forks and other bits too. Following with interest.
____________________
Triumph Street Triple-R
Sold: Honda Hornet CB600F-Y / Yamaha YBR125

[MarkJ]

Done lots of work on it but the pictures don't really show it unfortunately. I also forgot to take some pictures - I had to separate the front brake brackets from the calipers with a hammer as the sliding pins had seized. These are now greased up with silicon grease and move freely.

I also filled it up with coolant, which was leaking hat high RPMs. I'd just forgotten to nip up a coolant hose jubilee clip so that was an easy fix

I hadn't copper greased the front engine mounts. The bolt siezed in last time because of this so I don't want to have to drill it out again.

Grease:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01085.jpg

In:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01087.jpg

Exhaust on properly with all gaskets
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01089.jpg

Makeshift petrol tank
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01093.jpg

And running (quitely now it has the gaskets in)
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01094.jpg

I bought a new front wheel with discs as the front wheel had a ding from hitting a pothole and the previous discs were warped.
Tyre fitted:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01105.jpg

"Balancing" the wheel - didn't need weights
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01106.jpg

Old wheel
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01107.jpg

New one fitted
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01110.jpg

Everything back together
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01111.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01113.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01114.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01116.jpg

Very close now. Just need to:
Solder new wires for horn in as the current wiring join has corroded.
Fit new pads front & rear (waiting for delivery)
Bleed front & rear brake lines
Align rear wheel and set chain tension
Fit brake line P clips front & rear
Fit new rear tyre
Make sure all bolts on the bike are tight
MOT

[MarkJ]

I put a few fastners and stuff in some vinegar to work off some of the rust. Comparison of the end washer things that go on the rear spindle:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01117.jpg

Did the brakes tonight too

Pads in
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01119.jpg

Reverse bleeding saves so much time, I bled the rear brake from empty in 5 minutes. Force the fluid through until it appears in the reservoir:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01120.jpg

Then bleed normally to get the little bits of air out
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01123.jpg

Done
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01124.jpg

I did the same process on the front but didn't get any decent photos, I was too busy juggling calipers and pads

[DrDonnyBrago]

This is a very satisfying thread to read.

Good work

[MarkJ]

Cheers

[MarkJ]

Did some more today. Fitted the horn, P clips and checked all bolts.

Reason why the horn wasn't working:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01129.jpg

I nicked the horn off the track bike so had to make the mounting hole bigger
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01128.jpg

New wires and connections soldered & shrink wrapped
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01130.jpg

Red & black wire wrapped in electrical tape and fitted to horn
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01131.jpg

Front brake line P clips on
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01132.jpg

...and rear
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01133.jpg

I filled the fuel tank with petrol but it wouldn't run. It was fine when run using the funnel as a tank, so must be tank related as the fuel line wasn't filling up with petrol. I initially thought I'd kinked the small vacuum hose that opens the tap diaphragm, but that was fine. I opened the tap assembly and the diaphragm had just stuck - I gave it a gentle nudge and it freed up. Engine would then run

All being well tomorrow I'll fit the new rear tyre & re-solder the wiring under the tank - the indicators and some idiot lights aren't working occasionally, it's done this in the past and was just some broken wires where they flex when the bars are turned.

Then I just need to find the numberplate and buy a rear reflector

[Clanger]

[anthony_r6]

I did the same thing with all my bolts and washer parts to get the rust off. It does take the grime, dirt and rust off nicely, but ultimately they rust up very quickly again, worse than before, if you don't treat them somehow.
____________________
Ted : "Maybe he's agoraphobic."
Dougal : "Jack scared of fighting? I don't think so, Ted."

[MarkJ]

I used to have a bit of carpet at the back but it got soaked with oil and was a bit minging Going to try and get my hands on some nice lino when I get a bit more space in there

Yeah I've done the vinegar trick with bolts before, took em about a couple of months use in the rain and they went rusty again - I only did it to make them look a bit more presentable. Going to get them zinc coated at some point but I want the bike MOT'd first so I can be using it then zinc coat the bolts, paint the tank/mudguard/tail unit, and powdercoat the wheels and swingarm at my convenience