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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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#145 ·
Re: About to do a bunch of work to the bike; advice welcome!

Wait...does a 2001 FI bird even *have* a fan "thermo switch"? I read in another thread that the ecm controls the fan...did I read that right?
 
#151 ·
Re: About to do a bunch of work to the bike; advice welcome!

Wait...does a 2001 FI bird even *have* a fan "thermo switch"? I read in another thread that the ecm controls the fan...did I read that right?
Yes there is always some confusion but think about it ...... the ECM is only a 'dumb box' that only gives out commands when it is told something .... so there has to be a sensor/switch of some sort otherwise the ECM will just sit there being dumb.

Can't be certain but I believe the confusion is caused because some countries/states had 'emissions stuff' added and in that case the ECM has to monitor the temp and it can cause the fan to turn.
 
#146 ·
Re: About to do a bunch of work to the bike; advice welcome!

Ok just got out of bed. Went to the garage and pulled out the manual. Give me a minute
 
#147 ·
Re: About to do a bunch of work to the bike; advice welcome!

Page 19-23 in the manual. Switch is left side of radiator on the backside
 
#148 ·
Re: About to do a bunch of work to the bike; advice welcome!

That is on a 99. After 99 it seems that there is a cooling fan relay. Page 19-24 in service manual. Right behind the battery compartment under the seat.
 
#149 ·
Re: About to do a bunch of work to the bike; advice welcome!

4 in a row it is the far right if looking from the back of the bike towards the front.
 
#150 ·
Re: About to do a bunch of work to the bike; advice welcome!

 
#152 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks guys; looked around last night and I found "something" brass screwed into the thermostat housing that has a clip with 3 wires coming out of it, but that's as far as I got...didn't take any pictures as I *really* wanted to get my convertibars installed (#fail). The thermo switch I bought has a single "blade" connector coming out of the top, so it's different.

No biggie; I can always install a manual fan switch!
 
#153 ·
Re: About to do a bunch of work to the bike; advice welcome!


These are the mirror extenders from Twisted Throttle.
I can see much better now
 
#154 ·
Re: About to do a bunch of work to the bike; advice welcome!

Those are sweet! But they worry me for lane splitting...blast you Skully for going bankrupt!! I was so looking forward to removing my mirrors. :D
 
#155 ·
Re: About to do a bunch of work to the bike; advice welcome!

I would always want mirrors as a backup. I will measure the widest point when I get home.
 
#156 ·
Re: About to do a bunch of work to the bike; advice welcome!

37" from tip to tip.
You could always fold your mirrors in if you had too.
 
#157 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks Guy; that's not too bad actually. Once I get the bird back on the road I'll take a mental note of how much space I have when I split lanes, but those spacers don't look like they'd kill my opportunities.
 
#158 ·
Re: About to do a bunch of work to the bike; advice welcome!

Convertibars: just a shout out for Steve at Convertibars; great customer service! I contacted him about the struggles I was having with the bars and he's sending me a couple spacers that he makes just for that issue, for free! Just because he wants happy customers.

Yep...he now has another one. :)
 
#159 ·
Re: About to do a bunch of work to the bike; advice welcome!

Hey all, finally back from my biz trip and ready to get back to putting this bike back together!!

Question about throttle linkage: I've got the cables connected to my quick-turn throttle and to the throttle body linkage, and the throttle tube slid over the temp install of my new convertibar. With the throttle closed, if I look down the throttle bodies, the butterflies are visually closed. When I give the throttle 1/4 turn, and they are full open. Let go of the throttle, they snap back shut.

So...am I done? Will I need to adjust more once I get the bike back together and running? There's *plenty* of cable, so there's no way the cable will bind simply by turning the wheel lock-to-lock.

I'm just wondering if it's ok for me to put the air cleaner back on now and drop the tank back in place. I'd hate to have to take it all apart again if there's something else I should adjust while it's apart...thoughts?

Thanks!
 
#160 ·
Re: About to do a bunch of work to the bike; advice welcome!

A 1/4 turn from idle to full throttle? That would scare me! Glad you are baaack. Anxious for your first ride report after all of this. Especially the convertibars.
 
#163 ·
Re: About to do a bunch of work to the bike; advice welcome!

A 1/4 turn from idle to full throttle? That would scare me! Glad you are baaack. Anxious for your first ride report after all of this. Especially the convertibars.
Thanks man; I'm anxious too!! And I'm super curious about that 1/4 turn...we'll see if I just made a smooth bike twitchy. :) But others here have reported good things from the switch, so I'm hopeful.
 
#161 ·
Re: About to do a bunch of work to the bike; advice welcome!

Wild you should be good if it hangs a little you can back it out at the bar. One thing you want to check on is the pull back or push side return cable. Make sure it's not bending or lifting off the drum if it is it's to slack. Over time it will fray and break. So have a look at it. A little lift is ok but bowing is not good.
 
#162 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks B; I took a look this morning and it does lift a tiny bit...I'd say less than a MM...so sounds like I'm good.

Now if I could just find where I put the plug I made for the bottom of the air cleaner box (PAIR hose) I could finally drop the tank after 9 weeks of it being propped up on a stick!!
 
#164 ·
Re: About to do a bunch of work to the bike; advice welcome!

Made a little progress last night!

Lowered the pegs:


Oiled and installed K&N air filter and dropped the tank!

Experimenting with Convertibars placement. Had to unclip and reroute the cables going to the switch blocks, but had no issues doing it.



And finally, test fitting the new saddle! :)

 
#165 ·
Re: About to do a bunch of work to the bike; advice welcome!

Think I am going to try that lowering trick. I will be putting some washers in between the bracket and the peg in that gap for support though. Also, you better find an asbestos cinch strap. I will also use stainless bolts and washers. Once you Polish them they will stay shiny.
 
#166 ·
Re: About to do a bunch of work to the bike; advice welcome!

Guy, for the pegs you want a 2 1/8" long bolt if you're going to do it this way (rather than a pin and cotter pin setup); unfortunately I could only find a 2" or a 2 1/2" bolt at ACE Hardware. The 2" isn't long enough so I'm using the 2 1/2" and you can see that it's too long. I think it's 3/8" diameter but don't quote me on that. That black plastic spacer I have in there fit just a bit snug, so if I somehow fold the pegs up they won't snap back down like they would with the spring; I'll have to "manually" push the pegs back down. Not a big deal. The person here who originally posted it noted that you can use the springs from the opposite pegs...if I find the post I'll link it.
 
#169 ·
Re: About to do a bunch of work to the bike; advice welcome!

Guy, for the pegs you want a 2 1/8" long bolt if you're going to do it this way (rather than a pin and cotter pin setup); unfortunately I could only find a 2" or a 2 1/2" bolt at ACE Hardware. The 2" isn't long enough so I'm using the 2 1/2" and you can see that it's too long. I think it's 3/8" diameter but don't quote me on that. That black plastic spacer I have in there fit just a bit snug, so if I somehow fold the pegs up they won't snap back down like they would with the spring; I'll have to "manually" push the pegs back down. Not a big deal. The person here who originally posted it noted that you can use the springs from the opposite pegs...if I find the post I'll link it.
Hacksaw?
 
#167 ·
Re: About to do a bunch of work to the bike; advice welcome!

Whoa...I just realized that I'm actually really, really close to finishing this thing! All that’s left is to install the grips and the bar ends/throttlemiester, hook up the brake and clutch master cyl hoses, then fill the bike with fluid (brake, clutch, coolant, and oil), and it’ll be ready for a couple shakedown runs up and down my street! After that, troubleshoot/adjust anything that isn't right, wash the engine compartment a bit, wash and install the plastics, and it’ll be ready to roll.

Wow...now I'm motivated!! If I didn't have somewhere to be all day tomorrow I could possibly have this thing done this weekend! Well, I'll shoot for next weekend.
 
#168 ·
Re: About to do a bunch of work to the bike; advice welcome!

Are you sure you want to finish it . . . looks like you had so much fun working on it :eyebrows:.
Looking forward to get your feedback onthe 1/4 turn throttle. It's a mod I have on my radar . . .
 
#170 ·
Re: About to do a bunch of work to the bike; advice welcome!

Hacksaw...that actually works? I thought that would mess up the end so bad that a nut wouldn't go over it. Clearly I have a lot to learn. :) I did discover my hacksaw in a box in the garage, but I don't have a vise. Hmmm...I *do* have a c-clamp though. Ok, may give that a try sometime. Thanks again B!
 
#172 ·
Re: About to do a bunch of work to the bike; advice welcome!

Hacksaw...that actually works? I thought that would mess up the end so bad that a nut wouldn't go over it. Clearly I have a lot to learn. :) I did discover my hacksaw in a box in the garage, but I don't have a vise. Hmmm...I *do* have a c-clamp though. Ok, may give that a try sometime. Thanks again B!
Clamp it between 2 boards and saw away use a file to dress the end of the threaded section pushing away form the end and you'll be able to put a nut back on it.
 
#171 ·
Re: About to do a bunch of work to the bike; advice welcome!

BTW, I got the oil and the coolant in the bike last night and actually fired her up!! So excited to hear that beautiful noise again after so long!!!

May have some more time to work on it tonight; if so (and if somebody can help me identify a part I found in my clutch master cylinder) I'll add clutch and brake fluid. We'll see if I have time for the grips or not.

So close!!!
 
#173 ·
Re: About to do a bunch of work to the bike; advice welcome!

Nice; will try that sometime!

Clutch fluid filled and bled! Used the vacuum pump to get the fluid started, then just the speed bleeder. No bubbles, close the bleeder. Bam...done. Easy Peasy!

Fired her up again and got her up to temp so I could get the thermostat open and circulating coolant. The fan came on at 210F indicated and held the bike at 214F in my warm garage for a few minutes. I think that's about what I was seeing before the coolant swap, so at least it isn't worse. :) Will check the coolant and oil levels tomorrow once it's cooled off.

Time to fill and bleed the brakes...looking up the sequence now.

Onward!!
 
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