Honda CBR XX Forum banner

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!
 
See less See more
#111 ·
Re: About to do a bunch of work to the bike; advice welcome!

It's the PAIR system; emissions stuff.

http://www.cbrxx.com/engine-airbox-exhaust-fuel-delivery/18984-pair-system-removed.html

I like what it's trying to do, but apparently an aftermarket exhaust and PCII cleans up the exhaust better than the pair system. Plus, I hear that during a dyno tune they have to block the pair system off anyway because it adds air to the exhaust, and messes up the readings. So I figured while I was unraveling the sweater, I might as well continue... :D
 

Attachments

#112 ·
Re: About to do a bunch of work to the bike; advice welcome!

BTW, blinkers:

If I hook the running light (blue) wire up correctly without the brake (red) light wire, I get running lights. As soon as I hook up the brake light wire, the running light goes out. Back to the ebay seller for more communication!


I contacted the Ebay seller with this info, even shot a quick video showing the issue. They replied "
That is normal situation,the item is correct.You can resell to others or send it back for refund."

Harumph. I doubt very seriously that was the intent of these blinkers, but looks like this seller is done with me and I'm outta luck...and out another 9 bucks. Would probably cost me 5 to ship them back. They're a sealed unit so I'd have to break one open to dig around inside and see if there's a solution. Probably not going to happen.

But, I *did* learn a BUNCH about add-on fuse boxes (ap-1, fz-1) and relays. I actually have a 4-post 30 amp relay laying around so I hooked the blinkers up thru it, just to see if that would make a difference, but it didn't.

Ah, well...
 
#114 ·
Re: About to do a bunch of work to the bike; advice welcome!

As long as you are continuing to pull that thread...as tall as you are I would think that the mirrors only show you your elbows...just bought a pair of mirror extenders from Twisted Throttle. Will let you know how they are. They are 40 mm thick instead of 26 as from JAWS. Working on memory here but pretty sure those numbers are correct. I think they get them made as needed. Said they would be stocked in September but they just showed up. Would post a picture but I keep getting a "Editing not supported for this image" don't know what changed.
 
#115 ·
Re: About to do a bunch of work to the bike; advice welcome!

...as tall as you are I would think that the mirrors only show you your elbows...just bought a pair of mirror extenders from Twisted Throttle. ... Would post a picture but I keep getting a "Editing not supported for this image" don't know what changed.
I was *this* close to removing my mirrors altogether. Stinkin' Skully!!

I've thought about those extenders, but then I though about lane splitting. I may try a couple of those little blind spot mirrors instead; I had those on my CX500Turbo back in the day and they worked great, but if they don't then I'll be trying the extenders.

BTW I had a lot of issues uploading images last night...might be a "site" thing...
 
#116 ·
Re: About to do a bunch of work to the bike; advice welcome!

Just hopped on after putting the extenders on. Wondering why I waited so long and kept lifting my arm or elbow to see. Now all I see is the outside of my arms and what is behind me. If this is what stops you from white lining then you live very dangerously. I used to live on the bay. These really don't widen the bike enough. My legs are dear to me!!!
 
#117 ·
Re: About to do a bunch of work to the bike; advice welcome!

Ok cool; post pics when you can! I only split lanes when filtering up at traffic lights, and sometimes it's a close shave (but at 10mph it's easy enough to stop or maneuver), so I don't know how much (if any) those extenders would hinder that. Hopefully they aren't wider than your knees!
 
#118 ·
Re: About to do a bunch of work to the bike; advice welcome!

I used to white line on the 84 wing on the major hwy around the Bay. One time I walked down the pier and saw all the guys on the sport bikes. When I fired mine up they all started their's. Hey what's up? If you can fit then we know we can fit. Lead on...
 
#121 ·
Re: About to do a bunch of work to the bike; advice welcome!

BTW, and this weekend I did get a small amount of work done on the bike: in addition to the above mentioned (failed) bobbin cleaning, I put my calipers back together, installed the forks and top plate (fish scale pull is still around 5-6lbs), and installed most of the brake hoses onto the forks. Attempted to check my spark plugs; need to find some fuel hose to remove/install them properly. Wow, those are tricky! Glad I had a wobbly socket joint thingy laying around.

I also ran across a thin aluminum plate that just happens to be big enough to cut out two PAIR valve plates! I'm going to ask around at work and see if anybody knows anybody who could cut that out for me. Then just a bit of RTV and I'll be blocked off!

Oh...and...my daughter finally wore me down: we bought a dog. Sheesh.... :) (4 year old Malteese from an animal rescue shelter.)
 
#122 ·
Re: About to do a bunch of work to the bike; advice welcome!

Oh! woof woof!!
 
#123 ·
Re: About to do a bunch of work to the bike; advice welcome!

Say "hello" to my little friend...CB at least will appreciate this! :D

Dog Mammal Vertebrate Dog breed Canidae
 
#125 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks B. This is my current selection; would any of these work? The wheel is off the bike, so no worries about getting stuff on the brake pads.

If none of these will work I'll pick up some pb blaster tomorrow.

 
#126 ·
Re: About to do a bunch of work to the bike; advice welcome!

Couldn't move a single one of them by hand
if you can move them with fingers alone they are worn out ...... or you have very expensive brembo (or similar) fully floating discs. Are they turning at all? Usually takes a fair old leverage on a T'bar and tight pinch bolt to get the initial free-up if they haven't been tended before. I use a dry spray lubricant to get things moving ......
 
#127 ·
Re: About to do a bunch of work to the bike; advice welcome!

if you can move them with fingers alone they are worn out ...... or you have very expensive brembo (or similar) fully floating discs. Are they turning at all? Usually takes a fair old leverage on a T'bar and tight pinch bolt to get the initial free-up if they haven't been tended before. I use a dry spray lubricant to get things moving ......
Oh wow...I've watched 4 different videos on youtube and in each one when they are done they can move the bobbins by hand. I think I trust you more than random youtube guys, but...you are definitely different than the "norm" on this one! (You've probably never been accused of that before :D) So, maybe I'm done with my bobbins? They do twist with a ratchet and a pinch bolt, just not by hand...
 
#128 ·
Re: About to do a bunch of work to the bike; advice welcome!

I use PB Blaster. WD40 will dry and be sticky. Have lived this on my reloading press.
 
#132 ·
Re: About to do a bunch of work to the bike; advice welcome!

Keep hydrated then Wild know the feeling eve though I have air in the garage. I spent 6 hours Saturday using the homemade manometer from another thread to balance out the Bird. PIA but worth the effort I now have a dead smooth idle.
 
#133 ·
Re: About to do a bunch of work to the bike; advice welcome!

Yeah; my 20oz cup of water is always on in the garage with me! Saturday mornings are the best here because I can turn on the AC in the morning and get a lot of hours in...I'm sure glad I have FI and not carbs!

This town is way more humid than people admit. "It's 107F, but it's a *dry* heat" is the typical saying, but that just ain't so. I lived in the Farmington NM area for 10 years at 5500 ft. THAT was dry heat! This? Not so much. :) Turning the AC on after I get home at 5:30pm is useless; it would take until the next morning to cool the place down. :) I've found that after 9:30pm it becomes bearable in there, so that's typically when I'll be working on it this week.
 
#135 ·
Re: About to do a bunch of work to the bike; advice welcome!

While you're in process, I have a Manometer from MotionPro I could lend you. Really seal the deal on all your efforts. -BIG DAN:thumb:
No way man; I bought an '01 just so I wouldn't have to mess with carbs! :D
 
#137 ·
Re: About to do a bunch of work to the bike; advice welcome!

They still have butterflies in the throttle body.
 
#138 ·
Re: About to do a bunch of work to the bike; advice welcome!

What? Ugh...don't tell me such things! No I will not look up how to sync throttle bodies. I will not...nuts...I just looked it up. :D
 
#139 ·
Re: About to do a bunch of work to the bike; advice welcome!

Spent a few hours in the garage last night! A friend stopped by earlier in the day so I showed him my bike...he looked around and said "this scares me!" :D Yeah...it's in pieces, that's for sure! But this guy is very talented at "making" things, like several of you here, so I bent his ear about a couple things. First, my Shad top case / SwMotech mount: we figured out a good way to get the thing sturdy and mounted a bit farther back; he says it should take less than an hour to make it happen. Sweet! I'll take the pieces to him next week. I also talked to him about my thin aluminum plate and how to cut it to use as pair block-off plates. He says "10 minutes". Cool...I'll be taking that over to his place next week as well, and won't have to pay for block-off plates. :)

Then we talked about my new blinkers, and I ended up deciding to simply wire them as running lights and signals, and not worry about using them as brake lights, since it was one or the other.

So after 9:30 I got to work. I got the bobbins all "done", but not real happy with the results. Seems like all but one or two have a "high" side. So with the pinch bolt in and a ratchet, I turn a bobbin. The "grinding" is all gone now, so I know the gunk is out of them; but as they rotate they go from smooth and firm-but-easy-to-turn to smooth but very hard to turn, then back to "firm-but-easy-to-turn". I suppose these can probably get flat spots if left unattended? Figures! Well, I just turned each of them to the "firm-but-easy-to-turn" position and left them. Maybe they'll stay. The disks seem to be freed up a bit now. I didn't mount the wheel / calipers as I'd planned because I ended up washing the wheel/rotors to be sure there's no slippery stuff on them. I set the wheel aside to let it dry and got distracted by my blinkers, so I worked on them. :) Got those all soldered up, tucked away, and the back end buttoned up. Not too bad looking; at least they're a little different and make the bike a little more "mine".

Whew...making progress finally! Will work on the wheel and calipers tonight.

Oh, and I broke down and bought a G2 Quick Turn throttle that somebody here suggested. I was stressing about how much work it was going to take to make the Yamaha throttle tube work and said screw it; I have better things to stress about. So I found one for *way* cheap ($67.50 rather than $79) at SoloMoto (never heard of them before) and bought it. Should be shipping today.
 
#142 ·
Re: About to do a bunch of work to the bike; advice welcome!

Yay, another couple hours worth of work done last night! In this episode: front wheel mounted (mostly), pair block-off done (mostly), spark plugs removed, right caliper installed (mostly). Read on if you'd like, but if not, that's the summary. :)

As typical, not a whole lot got finished, and I was very easily distracted/redirected. :) (I don't have ADD, I have ADOLS: Attention Deficit...Oh Look, Squirrel!)

I mounted the front wheel...finally! Then realized I didn't have my laptop with The Manual handy, so no idea what to torque the bolts to. No worries; I'll just leave them loose while downloading the manual onto my phone.

As that's happening, SQUIRREL! I picked up the thin aluminum square that I want to use for pair block offs and had a distracting thought, so I started rummaging around thru some unpacked boxes. Hmmm...there's a c-clamp and a hack saw! Forget taking this to my buddy; instead I spent the next 40 minutes measuring and cutting and sanding and fitting. I only then decided that this is literally a HACK JOB, and I should have taken it to my buddy! But...now I don't have enough of that sheet left to make 2 new plates, so forget it: as Beestoys suggested somewhere else, I just popped the reed valves back in and put the original covers on, and will grab a couple hose block offs from maybe AutoZone on my way home today. Cheap fix, and no RTV to worry about since the reed valves have that rubber gasket around them. DONE! (Mostly)

SQUIRREL! You know, since I'm in here...what *do* those spark plugs look like? Thankfully I somehow have a "skinny" spark plug socket that has a rubber insert, a wobbly connector, and some extensions, so removing the plugs wasn't terrible. Turns out they're NGK iridium plugs (IMR9A-9H). Will post pictures later tonight and ask what you guys think of their condition, but they seem to be in good shape. Didn't have the manual with me so I didn't know what gap to check for.

Ok right..the manual! I forgot that I'd started downloading it. But as I'm reaching for my phone, I see the pages for the caliper install that I'd previously printed out, and...SQUIRREL! I went and grabbed the right caliper and installed it. Except I had put a piece (brake pad upper holder, opposite side of the screw-in pin) in backwards, so the caliper wouldn't go on all the way. :) Had a moment of panic thinking I'd have to take the calipers apart again, but no...simple fix. (Unscrew pin, remove pads, remove the holder and put it back in the correct way, pads, pin, torque, cap, done.)

But...as I feared, the LL Speed Bleeder is mostly in the way of the upper mounting bolt; I can get an open end wrench on it but not a socket, so no accurately torque-ing that bolt. :-( (Thinking about it now, I guess I could remove the bleeder and torque the bolt, then re-install the bleeder.) I tightened it by feel, and torqued the bottom mount bolt. I'm going to have to test if I can even use that bleeder...I may be buying a shorter one. Drat.

Then I got the brake lines connected. The new Hel line fits, but they supply a 9/16" steel bolt with copper washers. That sits above the OEM hose with a black 12mm bolt with silver washers. That's gonna drive me nuts, and I'd have to carry another wrench in my tool kit? I'll probably see if I can use the old OEM nut/washers. No, I don't have OCD. I have CDO, because that's alphabetical...as it should be!! :D

Whew...progress. Sort of!
 
#143 ·
Re: About to do a bunch of work to the bike; advice welcome!

Wow, more progress! Tonight: plugs cleaned up/gapped/re-installed, front wheel installed/torqued, front calipers installed/torqued, brake hoses (on calipers) installed/torqued!

Automotive tire Tire Wheel Vehicle Auto part

Tire Automotive tire Wheel Vehicle Motor vehicle
 
#144 · (Edited)
Re: About to do a bunch of work to the bike; advice welcome!

Last night and tonight, I removed the jack from under the bike...she's now resting on her own two wheels!! Well, ok; her front wheel and her center stand. :D

Installed the G2 quick turn throttle, and sure enough, I now have a 1/4 turn throttle. :D Can't wait to try *that* out!! Haven't done the "fine" adjusting of the cables yet; gotta get the tube on the convertibars first.

Cleaned up the garage a little, arranged my tools a bit, then drained the oil and the coolant. Will hopefully fill them up tomorrow evening.

Having a heck of a time with the convertibars; can't get the reservoirs anywhere close the to "inside' position when the bars are pointed the way I want them pointed. Have contacted support, but have a feeling I'm going to have to use a spacer on the front side of the bars...and hope that doesn't make the reservoirs touch the fairing.
Hand Auto part Technology Finger Electronic device


Leaving for a week-long biz trip this Sat, so another couple weeks with my bike sitting in pieces. Ugh. Ah, well...
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top