Project GOOF! - Honda CBR '91

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

It's not going to a full blown project, rebuild etc... Just doing a few bits and pieces that needs doing to the bike, and I thought I may as well share some of the pictures and what not with everyone else!

I should add that I am a complete novice when it comes to mechanics and the sort of thing. I have replace my down pipes (although I did snap a few bolts in there Shocked

), I've replaced my spark plugs (which turned out to be a royal pain the arse on this bike), changed oil etc... But I'm all for learning! Smile

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My Project - Honda CBR 600 F2/FM

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

Fast forward to now and it's winter! The bike has been in the garage for the last couple of months, but I'm going out for a wee ride today! Mr. Green

My radiator burst a few months ago and is currently sealed with RadWeld. Since I quite fancied doing some longer rides this year, I thought I better get it sorted! I didn't want to be out a 200 mile run and my radiator to start pishing out fluid again! So, I received this today:

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0006.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0007.jpg

Not bad considering the age of it, eh! Very Happy

I was looking at a few others but they don't even come close to the condition of this one!

I was planning to fit it later today, but I've still got another 2 weeks off work, so plenty of time to get it done!
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My Project - Honda CBR 600 F2/FM

Maruchino · Spanner Monkey Joined: 02 Jul 2009 Karma :

Good job on the paint!

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

Ok so today I decided to tackle my radiator and get it changed over! I was excited at the thought of dismantling my bike! I started off by draining the current fluid:

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0064.jpg

Now, I'm pretty sure it's not supposed to be that colour Sick

I then for the first time, stripped down ALL of the fairings! Very Happy

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0065.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0066.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0068.jpg

I thought it looked quite mean! Twisted Evil

Then I removed the old radiator, which was looking a bit worse for wear

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0073.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0070.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0071.jpg

I then fitted the much better looking radiator

https://i4.photobucket.com/albums/y118/Wonderboy_001/IMG_0006.jpg

I didn't take any pictures of it fitted to the bike, but you get the idea!

I then set about putting everything back together, but I've left all the side and rear fairing off to make it easier to add my antifreeze later tonight.
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My Project - Honda CBR 600 F2/FM

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Jamie S · World Chat Champion Joined: 28 Dec 2006 Karma :

Just a thought, might it be worth getting the bike up to working temp, and MAKE sure the new fan kicks in, it might appear in good condition, but may well not work/be faulty.
You don't want to find the fan to be nackerd on a hot day ! Shocked

Jamie

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

@Chis - Aha, I see what you mean Cool

Jamie - Good idea. Just came in from the garage just now after putting the new fluid in, but it's a bit late to be running the bike. I'll get out tomorrow and just let it idle for about 10 minutes, hopefully that should be enough for the fan to kick in!
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My Project - Honda CBR 600 F2/FM

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

So I thought I would update this with some more progress on the bike! It's currently off the road with no tax, MOT or insurance. Although, that's going to change soon!

When the bike was last on the road, I was having problems with the back brake; it was almost non existent and I had no feel through the pedal. So I decided to strip and clean the brakes.

First challenge was to get the pistons out. I had a dry system so couldn't use fluid to push then out. I resorted to using a car/tyre pump, was a pain in the arse and it took forever. Trying to get a good sealed air connection was a nightmare. Anyway eventually took the first piston out and gave it a little clean:

https://i4.photobucket.com/albums/y118/Wonderboy_001/7d891cf2.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/d4b9a557.jpg

Taada!

Took the slider pin out of the rear calliper, needed a bit of a clean!

https://i4.photobucket.com/albums/y118/Wonderboy_001/3ea53996.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/504aaeff.jpg

Took all the seals off and cleaned behind them

https://i4.photobucket.com/albums/y118/Wonderboy_001/19e03712.jpg

This was was a bit of a mess!

https://i4.photobucket.com/albums/y118/Wonderboy_001/c219fe49.jpg

After a clean

https://i4.photobucket.com/albums/y118/Wonderboy_001/aa8fba1f.jpg

There was also a chip out of this one, but it didn't seem to be leaking before so should be ok.

Also cleaned the sliders

https://i4.photobucket.com/albums/y118/Wonderboy_001/cf82aa9a.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/e572ab06.jpg

Everything went well for a change! Nothing broken (unheard of) Smile

I need to get done red rubber grease before re-assembling everything.

I'm collecting my calliper bolt (snapped it a few months ago) from Honda tomorrow and I'll try pick up a new pad pin as one of them has started to round which makes it a pain in the arse to get out!
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My Project - Honda CBR 600 F2/FM

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

And an updated picture:

https://i4.photobucket.com/albums/y118/Wonderboy_001/1ec12aab.jpg

I really enjoy tinkering about with the bike and learning new things (mechanically) as I've never done anything like this before.

Any ideas to what else I could do on the bike to keep me busy?

Oh lastly, what's everyone's opinions on the stickers? (more visible on the top pictures) Not sure whether to remove them or not.
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My Project - Honda CBR 600 F2/FM

Nick 50 · World Chat Champion Joined: 24 Jul 2011 Karma :

The stickers don't look that bad to be honest.

As for tinkering..........

How about the back end?? Swing arm off, check rear suspension. Give it all a good detailing especially round the front sprocket, my CBR was horrendous round the front sprocket.

Quick question, how did you clean the brake pistons? Reason I ask, is they look "gold'ish" coloured, is that a protective coating?

I get a bit obsessive when cleaning and on the GZ took the coatings of lots of stuff which started rusting. Had to get them recoated Embarassed

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Current Bikes: ZX7r 97 (Black Beauty), VFR400 NC24 (The banana)
Previous Bikes: Aprilia Tuono 03 (The Beast), CBR600f (97)
First bike: A GZ125 Lemon.......

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

Harley · Two Stroke Sniffer Joined: 14 May 2012 Karma :

What type of paint did you use on the forks? mine have the same kinda corrosion and I was wandering what you used to get such a nice finish?

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

TUG · World Chat Champion Joined: 12 May 2007 Karma :

Steven, Dont go too mad with the green pube pads Laughing

make sure you clean out the grooves where the seals fit too. Thumbs Up

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Haz ER-5, innit!

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

So rather sadly the bike hasn't left the garage since the last update! I've decided there's no point in the old girl sitting in the garage all year, so I've decided to start prepping it for spring.

I left the Calipers sitting out with the bleed nipples off and this caused the brake fluid around the caliper to crystallise

https://i4.photobucket.com/albums/y118/Wonderboy_001/05925C38-B7BA-48AA-8262-76DC4DA968A8-1410-000001A48D5109ED.jpg

Fearing that the seals would be covered in the same gunk, I've have decided to strip the calipers again to give them a good and proper clean. I have orders a set of piston pliers (hopefully they will do the trick) and a 100mm syringe to reverse bleed the brakes. Updates to come shortly!
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My Project - Honda CBR 600 F2/FM

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

The bike has done just over 30k miles and I'm not sure if the valve clearances have ever been checked! I decided to tackle this milestone today!

I removed the side and rear fairings, fuel tank, air box and housing and the HT leads and control box (not sure what its called).

Air filter looks brand new even though i've owned the bike for 2 years and never changed it.

https://i4.photobucket.com/albums/y118/Wonderboy_001/83A264DC-FD42-4018-B5B5-BCB0A2DF4823-343-00000043883752BA.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/070F7D02-D5F6-42FE-94E4-E6A43BFD0954-343-000000438FFDF3C3.jpg

And how it stands

https://i4.photobucket.com/albums/y118/Wonderboy_001/A514B238-9E20-4090-B388-EC37C95FBB06-343-00000043A0E652BD.jpg

I'm a little unsure of what to so next, so hopefully with a little help from forum members ill get there!
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My Project - Honda CBR 600 F2/FM

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

What's still to be done and buy

Check valves and adjust as necessary
Flush + change coolant
Oil + filter change
New cam chain tensioner
Double bubble screen
Strip and re-build calipers
Change bulb dials
Charge Battery
Inspect chain + sprockets

Not much then Rolling Eyes

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My Project - Honda CBR 600 F2/FM

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

Set about stripping the bike further today:

https://i4.photobucket.com/albums/y118/Wonderboy_001/5AF6973C-0748-4893-B9A1-9943A23702D0-343-000000D12541C457.jpg

https://i4.photobucket.com/albums/y118/Wonderboy_001/6DD6E827-FCC5-4263-89E9-6095C5A918FA-343-000000D11DBEE94A.jpg

and eventually got the cam cover off:

https://i4.photobucket.com/albums/y118/Wonderboy_001/765BCD11-B5F9-45D7-90B1-6E96401F243A-343-000000D13608C648.jpg

Measured all my valve clearances

https://i4.photobucket.com/albums/y118/Wonderboy_001/DB2ACAEE-02BB-441F-8FD0-4ADD657EAE27-343-000000CE85E3A6F0.jpg

As you can see surprisingly most of them are on the limit and only two are out by 0.01mm bellow the tolerance. I'm not sure whether I should go ahead and change the shims or leave it another 8k miles.

Kind of left it like that for tonight. Purchased some Anti-Freeze today so that's maybe the next job.
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My Project - Honda CBR 600 F2/FM

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Why wouldn't you sort them? Do the lot IMO. You have it apart and know the sizes you need. Once done you won't need to touch it again for several thousand miles. Is it shims out lock nuts?
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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

stonesie · World Chat Champion Joined: 04 Jul 2010 Karma :

They look like Shim-under-bucket, get them all to the slack end of the tolerance and they should be fine for a good while.

Edit
It's a job I keep putting off on mine but it needs doing, one handy tool I need to go and buy is a magnet on a stick (pick up tool) it will keep the shim stuck in the bucket.. Dropping the shim into the engine could be bad depending where it settled.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

StevenF · World Chat Champion Joined: 25 Apr 2008 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Low tolerance is bad, they usually tighten up not loosen, AFAIK.

It probably would be 'fine' for another 8k but you would have to do it then anyway. Like I said you would only have to take it apart and re measure everything then order the shims and wait etc. just do it now while it is apart. Set all of them toward the looser end of the tolerance IMO.

Edit: affect on the ride,

Loose - lower performance
Tight - over heating and damge to the valve train.
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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

Jefr0 · World Chat Champion Joined: 29 Jul 2007 Karma :

Interesting little project you got going on.

Nice colour scheme Razz

I'd be interested to know if you went by a guide or Haynes for the valve clearences? Also, what do you need to take to get off to get to them? I've got new spark plugs to go in mine also.

Where would you get new shims from, shops wise so you don't have to wait days for delivery on net?

I'll be keeping an eye on when you do the cam chain tensioner too, I'll be needing to do mine.

I suffered the same with the brakes, rebuilt them and they're fine now Thumbs Up

What's your battery like? I think I need to invest in a motobatt, but going to do the valve clearances/spark plugs first (not touched in at least 6 years!)
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Rides: Honda XR 125 ('03) Honda CBR 600F ('91), Ducati 916 Biposto ('95)