Grotty Hornet

[MarkJ]

It's been a while since the last update but I have been busy, even though the progress doesn't look much - it's been fiddly jobs.

I changed the head bearings. If anyone comes to change Hornet head bearings, the bottom race sits on a rounded lip which doesn't give enough space to manoeuvre a normal drift past:
https://i47.photobucket.com/albums/f186/markjackson13/DSC00918_s.jpg

So I had to file a notch out of my drift like so
https://i47.photobucket.com/albums/f186/markjackson13/DSC00922_s.jpg

Fitted the taper roller bearing on the bottom race, also sanded off the powder coat from inside the yokes with a dremel:
https://i47.photobucket.com/albums/f186/markjackson13/DSC00925_s.jpg

I fitted some worn out Pilot Road 2 tyres to my wheels so I can have a rolling chassis. These will be replaced when the bike is complete:
https://i47.photobucket.com/albums/f186/markjackson13/DSC00924_s.jpg

Put the forks back together with new bushes, seals and 15wt oil:
https://i47.photobucket.com/albums/f186/markjackson13/DSC00926_s.jpg

The rear shock is pretty grubby, but as with all Hornet shocks it has eventually turned into a bouncy castle suspension component. Supposedly getting them re-done is pretty difficult and the shock goes off eventually so I'm going to see if I can get my hands on a second hand Nitron/Hagon/Ohlins jobby. In the mean time I didn't want to look at the grubby shock, so being a tight arse I made myself a shock sock out of some neoprene sheet off ebay
https://i47.photobucket.com/albums/f186/markjackson13/DSC00927_s.jpg
https://i47.photobucket.com/albums/f186/markjackson13/DSC00928_s.jpg

Turn it inside out, pop some holes in for the string and:
https://i47.photobucket.com/albums/f186/markjackson13/DSC00929_s.jpg

Finally I fitted it all together to get my rolling chassis
https://i47.photobucket.com/albums/f186/markjackson13/DSC00930_s.jpg
https://i47.photobucket.com/albums/f186/markjackson13/DSC00931_s.jpg
https://i47.photobucket.com/albums/f186/markjackson13/DSC00932_s.jpg
https://i47.photobucket.com/albums/f186/markjackson13/DSC00933_s.jpg
https://i47.photobucket.com/albums/f186/markjackson13/DSC00934_s.jpg

Next job will probably be to re-do the paint on the underside of the engine, blank off the PAIR inlets, check valve clearances then fit it in the frame.

[TUG]

Swing arm sticks out a bit don't ya reckon?

Amazing work though, can't fault you on anything else really, your determination is commendable.
____________________
Haz ER-5, innit!

[salty21]

quite liking the silver and black theme, starting to look like a bike again .
you planning on getting the rusty bits plated/replaced or does that enter into Tim... territory
____________________
04 NSR 125(sold) ---- 03 CBR 600rr(sold) ----90 pan euro ST1100 '' ----02 CG 125
94 CB400 Super Four ---- 2000 VTR SP1 (sold) ---- 08 ninja p8f(sold, meh) ----05 CBR600rr

[MarkJ]

[MarkJ]

Small update: re-painted the front of the engine.

These speckly bits were where it was lifting:
https://i47.photobucket.com/albums/f186/markjackson13/DSCF1885Copy.jpg
It was only like this on the underside of the engine - must have been crap that I hadn't cleaned off when I painted it the first time as everywhere else on the engine was fine. I used a tiny dremel wire wheel last time which wasn't much cop, used a big wire brush attachment for my drill this time:
https://www.alltradetools.com/catalog/644-668-large/410374-1-wire-brush-attachment.jpg

Before:
https://i47.photobucket.com/albums/f186/markjackson13/DSC00935_s.jpg

After:
https://i47.photobucket.com/albums/f186/markjackson13/DSC00936_s.jpg

[MarkJ]

Finished the PAIR blanking plates - I cut a chunk of aluminium out of my numberplate bracket to make the plates out of. Just mole grip'd the aluminium to an old bracket and ground it down with a cutting wheel till they were the same shape.

They just need cleaning up and deburring and they're finished.
https://i47.photobucket.com/albums/f186/markjackson13/DSC00939_s.jpg

Poorly focussed comparison:
https://i47.photobucket.com/albums/f186/markjackson13/DSC00938_s.jpg

[salty21]

regarding the swingarm bearings, this site is pretty usefull for finding bearing codes for hondas. I normally use hondapartshouse in the US but they dont show any hornets on their database.

they show codes/sizes for all swingarm bearings apart from the left side needle bearings. for those i would just measure the diameter of the spindle for the i.d and the bearing shell for the o.d and width

https://www.lingshondaparts.com/honda_motorcycle_parts_selection_pfk.php?block_01=13MBZ2I1&block_02=F__2200&block_03=1791
____________________
04 NSR 125(sold) ---- 03 CBR 600rr(sold) ----90 pan euro ST1100 '' ----02 CG 125
94 CB400 Super Four ---- 2000 VTR SP1 (sold) ---- 08 ninja p8f(sold, meh) ----05 CBR600rr

[Mikey3]

That's pretty awesome man. Like it!

I'm doing mine up but having no spare transport means that things such as engine paint and frame powdercoating makes mine a pain in the arse!

Mike
____________________
'04 Yamaha WR450F
'99 SV650 Streetfighter Project - mid build
'Motorcycling is about what you do; not about what you own, or how much you spend on it'

[N cee thirty]

never relised how little there is of the hornet frame

flexyy
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[Shinigami]

fancy cleaning mine up when you're done?
____________________
Current: Honda City Fly CLR125 2003 Honda CB600F Hornet 2008 Yamaha FZ6 S2 + 1991 Kawasaki GPZ500
"Once you realize what a joke everything is, being the Comedian is the only thing that makes sense.

[GrumpyGuts]

...and mine, bitch.
____________________
My Bikes: Lifan Beat 125cc '11 -> Suzuki B120P '76 -> Suzuki EN 125-2A '08 -> Honda CG 125 '04 -> Honda CB600F Hornet '98 -> Kawasaki ZZR 600 '99 -> Kawasaki GPZ 500S '95 (Current)
Theory test passed - 09/02/2012 >>>> Module 1 passed 24/07/2012 >>>> Module 2 passed 24/10/2012

[MarkJ]

Pfft, I've all on cleaning my own!

Thanks salty, I've used Lings before but never noticed the bearing dimensions, cheers.

[Redoko]

Anymore progress?
____________________
"Let's face it, this is not the worst thing you've caught me doing."
Sudika Sportsman SK50QT > Gilera DNA50 > Honda CBR125 RW7 > Kawasaki Zephyr750 > Suzuki GSXR600 > Honda Hornet CB600F '51

[MarkJ]

Yeah but not much, had a hectic few weeks so haven't had much time to do anything!

The valve clearances are all fine, but didn't think it warranted a new post. I'm off all next week so expect progress then, hoping to have the engine in by then

[suzukirider19...]

looks sweet! as the theme is black/chrome/siver i would polish the lip on the wheels think it would realy tie everything in
____________________
husky sm610

[R1AL]

Excellent thread...you're doing a great job mate.

[MarkJ]

Me again.

Can't believe this has been going on for nearly three years now. I've changed jobs internally at work and potentially might be having to do some reasonable miles on a bike (might be commuting into Leeds centre) so could do with having this finished soon.

The rolling chassis in the last update didn't have the head bearings greased, and all the bolts were just nipped up, so I tightened them all up to the correct torque and greased the head bearings.

I then took the wheels and forks off, and lowered the frame onto the engine to fit it in. Ended up with this:

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC00999.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01000.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01001.jpg

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01002.jpg
The carbs were an absolute bastard to get back on. Eventually had to wrap a ratchet strap around the engine and carbs and tighten that. Then head the inlet rubbers with a hairdryer and they eventually popped in with me practically hanging off one end of the strap to make it tighter.

Going to leave the removable bits of the engine (water pump, CCT, starter etc.) unpainted as a contrast to the black, if it looks daft I'll take them off and repaint
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01003.jpg

I was going to paint the oil cooler, but the muck is really ground in and I can't be bothered to spend ages wire wheel-ing it only for the paint to come off anyway. It looks fairly dark now anyway:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01004.jpg
That's going on in the next few days, I can't find the bolts for that so had to order some off the internet.

After that is the undertray and loom which I'm not looking forward to:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01005.jpg

Then the overflow tank after it's been cleaned:
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01006.jpg

And that's where I'm up to. Hopefully the only awkward job after the loom will be the coolant pipework and routing all the cables again. I have some pictures of everything before I took it apart so hopefully that'll make the process easier.

[Dean-J]

wow, i remember reading this yonks ago, had completely forgotten about it until just now!!

Fair play to ya, the bike was in a hell of a state when you started, i have literally broken better bikes down for spares!

Looks a million times better now though man, really coming along, gonna look good when your finished!!
____________________
Current: 99 Yamaha Thuundercat
Previous: K7 GSXR 1000 K4 GSXR 600 roadbike, CBR 600 Steelie Track bike, 2005 SV1000Sz, 2004 FZ6 Streetfighter,2003 Yamaha Thundercat, 2002 SV650, 1989 Yamaha DT125R

[TUG]

This thread is epic and I hope my ER5 resembles the same condition when I'm done with it as it currently sits in the same condition as this started off as.

You've done an amazing job Mark!
____________________
Haz ER-5, innit!

[Llama-Farmer]

Nice transformation, be nice to see the finished product.

Peanut butter will improve the look of the old rubber pipes... rub it in with a cloth, a bit like a polishing paste. I'd go for black Samco ones to replace the 3-pc coolant hoses and just tart up the old ones for the rest of the hoses/breather pipes etc.
____________________
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]

Thanks for the compliments

Not had much time tonight, so quickly put the loom in. Didn't have a chance to look at the photos for correct routing so some bits will probably need moving, but I wanted to get another thing on the bike.

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01007.jpg

[.Bishbash.]

Dude, that's looking GOOD!!
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Current bike - GSX-R1000 k8

[garth]

Those sprocket bolts offend me.

[MarkJ]

https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01009.jpg
Suck it, bitch

Cleaning them can be my next job, ok flower?

[MarkJ]

Not as much progress today as I'd have liked. The bolts I'd ordered for the oil cooler ended up being about 10mm too long as I'd measured the thread hole to be 19mm, however it was only threaded for about 10mm so had to spend a while chopping the bolts down.

Anyway, to appease garth the sprocket bolts were cleaned with a wire wheel and vinegar
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01013.jpg

Shiny bolts
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01014.jpg

Fitted the lock with the new bolts
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01017.jpg

And finally, the oil cooler fitted
https://i47.photobucket.com/albums/f186/markjackson13/hornet/DSC01018.jpg