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DONE! About to do a bunch of work to the bike; advice welcome!

17K views 199 replies 16 participants last post by  WildDoktor 
#1 · (Edited)
Well, the rear shock is done, so it's time to go thru the forks, right? I need to check what's actually in there and definitely change the oil. (None of the previous owners can tell me what exact mods were made to the forks...all they remember is that it's been "revalved" (but not, say AK-20s or other aftermarket). So I'm waiting on buying fork oil until I see what's in there.) What I found in there were 1.0kg springs and shorter-than-stock spacers. Now there are longer spacers, 10w oil and a 160mm air gap. Will ride this way and tweak as needed.


  • I also have a new set of convertibars and a Yamaha R6 throttle that I'm going to install.
    • Convertibars installed; working on final settings. What a pain. Scratched the heck out of my top clamp without realizing it while rotating the main mounting ring again and again for positioning. After many hours of tweaking (literally over 5 hours, spread out over several days/evenings), flipping the mounting ring upside down and back again, I only have the bars close to where I want them. There's no way to make them exactly match each other's settings, so as I sit on the bike I can tell that one bar has a slightly different orientation than the other. Frustrating. Will continue to tweak.
      • ​I finally got them where I wanted them and put the plastics back on...only to find that the bottoms of the stalks now hit the plastics. So I cut them off at the correct length, and now have full lock-to-lock steering. The throttle cables touch the windscreen a bit at full left lock, but it's not a deal breaker; the shield just flexes maybe 1/8" and all is well.
    • I have throttlemiester bar ends / throttle lock and got a ConvertiBars "kit" to install them, but so far I have no idea how these are supposed to mount. Still investigating.
      • Left side is simple: push in, tighten the bolt, done! The throttle lock takes a lot of messing around until you find the sweet spot, but I've found it and now have a working throttle lock.
    • R6 throttle got replaced with a G2 aluminum quick turn throttle because I wasn't comfortable with the mods needed to use the Yami throttle tube.
      • ​This G2 throttle tube *rocks*!! I LOVE the quick turn throttle. It really brightens up the throttle response, and doesn't make low-speed riding twitchy at all. If you're thinking of doing this...do it! You'll be pleased!
  • And since the convertibars came with clutch and brake lines, and longer throttle cables, guess I'll be doing the brake fluid and bleed and the clutch fluid and bleed (I have 7 speed bleeders on their way...the LL version.).
    • Ugh...do *not* get the LL version!! I had to return them and get the L version. Much better. Both hoses and all fluid changed and bled; used 1.25 bottles of Motul DOT 5.1.
  • While I'm replacing clutch line/fluid, might as well open the clutch slave cyl to check for crud. And clean out the front sprocket cover and check the sprocket.
    • It's gross in there! But now it's clean, and I no longer fear opening it up once in a while and cleaning it out.
  • Of course I might as well check the brake pads, right? (Have 2 sets of EBC HH Sintered's on their way for the front; rears are fine.)
    • Brake pads are fine, so I have a new set for another day.
  • And heck...probably better change the oil and the coolant too. (Unsure yet what oil and coolant to use...I know CB will recommend Motul! :D) Not going to replace hoses unless they're bad...those fancy ones are spendy!!
    • Done! Maxima SynBlend 10w40. 1 gallon...used the whole thing! K&N oil filter as well. O'Rielys 50/50 coolant, good for all motors. Also replaced the OEM air filter with a K&N.
  • And then there's the PB double bubble that should arrive soon.
    • Not only do I have the PB, but I bought a ZG touring, dark smoke. Haven't mounted either of them yet.
      • ​I decided to try the ZG first and I love it! Puts the wind right at my shoulders, not my chest, not up my helmet. One day I'll try the PB as well.
  • And I might as well check the spark plugs.
    • Checked them and they are fine. Cleaned them up a bit and re-installed them.
  • And since the body work will be off, the bike should get a good cleaning as well.
    • Pending...


Yikes...I've got myself a bit of a project. How did that happen?? :rotfl:

Parts and pieces and fluids are either already here or on their way, and I plan on having the bike down for a week or so to get it all completed.

Why do I have a feeling I'm going to be asking a lot of questions soon?? :D I've already done hours and hours of research here...invaluable info is to be had here!! :clap:

Anyway, just thought I'd share, and thank all of you in advance for the knowledge you've already poured out here that has given me the confidence to do this huge project!
 
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#36 ·
Re: About to do a bunch of work to the bike; advice welcome!

The valve is in the end of that cartridge. I don't think there is any tell tale ways to id the difference unless you have the specs for orfice sizes in the shims.
 
#37 ·
Re: About to do a bunch of work to the bike; advice welcome!

The valve is in the end of that cartridge. I don't think there is any tell tale ways to id the difference unless you have the specs for orfice sizes in the shims.
agreed but a very good indication would be the number of shims. The std set up has a few shims (can't remember off the top of my head how many) any re shimming nearly always increases the number of shims.
The other true indication is that the end of the damper rod is peined over at the factory and to do any re-shimming you have to grind this off ..... if this 'damage' remains no work has been carried out.
Have a look at this post http://www.cbrxx.com/suspension-tir...alve-install-pictures-added-2.html#post313659 and you will see what I am on about!
 
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#39 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks guys! How do I get the valves "out"? I removed that silver cap at the bottom, but don't see how the "innards" come out...

Product Auto part
 
#40 ·
Re: About to do a bunch of work to the bike; advice welcome!

There's a circlip buried under the valve. You need to push the valve up into the body to get at it.
 
#41 ·
Re: About to do a bunch of work to the bike; advice welcome!

Interesting...I'm unable to push the valve up into the body. Pushed with my thumbs, nothing. Put a socket in there that fit well and tapped it with a hammer, nothing...didn't budge.

So I'll assume this is the stock valving. :)

New advice needed now! With this stock valving, a longer-than-stock liner rate spring, and a shorter spacer tube up top, is 5W oil going to be ok? I'm trying to solve a bit of "harshness" in the forks.
 
#42 ·
Re: About to do a bunch of work to the bike; advice welcome!

That's similar to my setup and works pretty good for me. It's going to be ultimately your call but it would be a good start.
 
#43 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks B! I'm actually talking to my suspension guy (who fixed my rear shock) today at lunchtime; he's very keen on getting my front dialed now that he has my rear dialed, and I'm very curious to know what exactly he has in mind, and what that would cost!
 
#44 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks B! I'm actually talking to my suspension guy (who fixed my rear shock) today at lunchtime; he's very keen on getting my front dialed now that he has my rear dialed, and I'm very curious to know what exactly he has in mind, and what that would cost!
I'm betting a revalve at the least and he'll know how top get that critter loose from the cartridge.
 
#45 ·
Re: About to do a bunch of work to the bike; advice welcome!

I'm thinking revalve as well, at the least...all the way up to new AK20's or similar, or anything in between. :)

I'm suddenly starting to get really nervous about how much this bike is costing me. I think my current fork setup with 5w oil may have to be "just fine". We'll see what he wants to charge me.
 
#47 ·
Re: About to do a bunch of work to the bike; advice welcome!

Ok, back from Todd's place. I left the forks with him. To begin, we're going simple/basic: he's going to measure the spring weight so we know exactly what's in there. Then depending on what he finds he'll adjust the spacer, add the correct weight oil, and set the correct (for me) air gap. He'll put them together and get them back to me tomorrow. Once I can get them back on my bike and get the bike back on the road (probably not till this weekend...arrr!), I'll ride it, report back to him, and and he'll adjust them accordingly.

Or he could custom valve / shim them for about $500. Yeah...no can do at this time! :)
 
#48 ·
#49 ·
Re: About to do a bunch of work to the bike; advice welcome!

Went and picked up the forks from Todd yesterday...actually watched him work on them while I was there. This guy's obviously been doing this for years!

Looks like stock valving, which he didn't mess with. But it turns out my "shorter than stock" spacers are way too short, so he grabbed some spacer stock that he had and cut me some longer spacers. With those and the aftermarket springs, he decided that we will start with 10w oil and a 160mm air gap. Then he told me, and emphasized 3 more times, that "this is going to feel different!". :) This is *not* the final setup; this is simply the beginning, as a baseline. The front end is going to stand up taller now (at rest, with me on it), and the ride will be *much* different. I need to ride it with an open mind and report back to him what I'm feeling so he can begin setting it up to suit me.

By the time I got to the point of saying "Ok, what do i owe you?" I was nervous...figured I'd be shelling out $200-$250 for all his time and knowledge.

Nope...$60!

So, for $60 I had an expert work with what I have, make some mods, and now I can go back to him as many times as I need to and he'll listen to me, then make adjustments (again working with what I have) until I'm satisfied. Shorter or longer spacers, different weight oil, height in the clamps, and of course then adjusting the rear to match. All included in that $60.

Whew! I'm ok with this. :D Can't wait to get the bike back together!! Gonna be a while; between 104F and 106F all week this week, which means the garage will be a gazillion degrees.

Oh, and his last words as I walked out were: "Don't *even* think when we're done with this that "this" is as good as it gets! It'll be *way* better than it was, but nowhere near what it *could* be." :) Yep! All it takes is money... :D
 
#52 ·
Re: About to do a bunch of work to the bike; advice welcome!

My next question: completely replacing the brake fluid.

I've read loads about bleeding the brakes, but can't seem to find anything about replacing all the fluid completely, all at once.

I'm replacing all the bleeder valves with speed bleeders. I'm also replacing the above front brake hose.

So what should my sequence be to replace all the fluid?

I'm thinking:

1. Dump the front brake reservoir (upside down into a container since I have it off the bars at the moment)
2. Remove / replace front brake line
3. Replace bleeder valves on the front
4. Dump rear reservoir
5. Replace bleeder valves on the rear
6. Fill reservoirs
7. Bleed Brakes

Sound right?
 
#54 ·
Re: About to do a bunch of work to the bike; advice welcome!

Well, I had to read the manual 3 times before it finally "clicked"; after that it was fairly simple. Bought a mityvac knockoff from harbor freight and sucked all the juice out as per the manual, and replaced all my bleeder valves with speed bleeders. Should make it fairly easy to bleed from now on! I think I'll still have to use the mityvac to fill it, then bleed like normal.

Then I removed the front right brake caliper because I saw this post Brake Caliper Overhaul from B.I.R.D. and thought "looks easy enough; I can do that!"

New Questions:
Will any off-the-shelf brake cleaner spray bottle at Autozone or Walmart work to clean up the brakes?
My "slider pin boots" seem stuck to the slider pins. Does this mean I need new ones, or will spraying them with brake cleaner lube them up enough for them to come loose?
What type of grease should I use for lubing up the boots?
Can I remove the caliper pistons like he did without needing to replace the seals?

Yikes...guess I'd better get to work now. :D
 
#55 ·
Re: About to do a bunch of work to the bike; advice welcome!

Will any off-the-shelf brake cleaner spray bottle at Autozone or Walmart work to clean up the brakes?
Yes

My "slider pin boots" seem stuck to the slider pins. Does this mean I need new ones, or will spraying them with brake cleaner lube them up enough for them to come loose?
They should

What type of grease should I use for lubing up the boots?
I use moly

Can I remove the caliper pistons like he did without needing to replace the seals?
If your careful yes but don't pull the seals or your done and you'll need to replace them. Also be careful with the cleaner it may make the seals swell.
 
#57 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks guys! On my way to get cleaner, moly, and blue loctite. Any hints on how to get the pistons out? Fluid is drained and the calipers are off the bike...
 
#62 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks guys! On my way to get cleaner, moly, and blue loctite. Any hints on how to get the pistons out? Fluid is drained and the calipers are off the bike...
Very low air pressure with extreme caution them things will pop hard. I usually wrap them in a rag and trap them in a vise. Pop the first then just press it in far enough to seal and pop the second. AGAIN BE VERY CAREFUL !!!
 
#59 ·
Re: About to do a bunch of work to the bike; advice welcome!

You ain't kidding! This bike practically begs to be torn into, cleaned and polished.

Front right caliper, done!




Front left, in progress:


Levers, awaiting convertibars:
 
#61 ·
Re: About to do a bunch of work to the bike; advice welcome!

While you are at it...
I'm never gonna get this bike done...:rotfl:

Thanks Patuleia; that's actually super helpful...I never even knew how floating disks worked, or that those buttons were supposed to move freely! I'm absolutely going to do this *and* check the torque on those inner bolts as he suggested. Might as well; I want to be completely confident in my front end.
 
#63 ·
Re: About to do a bunch of work to the bike; advice welcome!

Researching replacing the head bearings, I read that a 1-11/16" socket will do the trick, as long as it's "deep enough". No specifics as to how deep it needs to be.

Can anybody confirm if this one will do the job? The description down below says it's 1.4375" deep.
 
#65 ·
#67 ·
Re: About to do a bunch of work to the bike; advice welcome!

Can't believe all the stuff you are tearing into. Is the family back from Disney? Better hurry and finish! Doing great!
 
#68 ·
Re: About to do a bunch of work to the bike; advice welcome!

Can't believe all the stuff you are tearing into. Is the family back from Disney? Better hurry and finish! Doing great!
I can't believe it either. :D Family got back a week ago...the minivan in the driveway (rather than in the garage) is my constant reminder to HURRY. :rotfl:
 
#70 ·
Re: About to do a bunch of work to the bike; advice welcome!

HOT is right; that's actually why this is taking me so long. I get home in the hottest part of the evening, and my garage has been baking in it all day, so yeah...a couple hours sitting in *that* heat and I'm completely cooked. Some days I can't do *any* work due to the heat. Even after opening up the doors / window and turning on a fan, it'll only get down to ambient temperature...but still, that's 100F or higher most days; just sucks the life outta you. How do you guys in AZ do it? Do you have AC in your garages? I'm contemplating getting a portable AC unit.

Ah well; #firstworldproblems! We're actually super blessed and I have nothing to complain about!! I'll have it all done eventually, and my wife can park in the garage again. :)
 
#71 ·
Re: About to do a bunch of work to the bike; advice welcome!

HOT is right; that's actually why this is taking me so long. I get home in the hottest part of the evening, and my garage has been baking in it all day, so yeah...a couple hours sitting in *that* heat and I'm completely cooked. Some days I can't do *any* work due to the heat. Even after opening up the doors / window and turning on a fan, it'll only get down to ambient temperature...but still, that's 100F or higher most days; just sucks the life outta you. How do you guys in AZ do it? Do you have AC in your garages? I'm contemplating getting a portable AC unit.

Ah well; #firstworldproblems! We're actually super blessed and I have nothing to complain about!! I'll have it all done eventually, and my wife can park in the garage again. :)
This Guy in the VERY HUMID MID WEST put an AC unit through the wall. A used unit so it didn't cost that much. Use it about 5 times a year. Makes a huge difference. No more sweat running down my arms into the engine.
 
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