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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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#2 ·
Re: About to do a bunch of work to the bike; advice welcome!

Latest oil, coolant, brake fluid
recommended.
also recommended.
Also recommended[emoji4].
recommended.
Current pads.
I use this, recommended.
Voltage regulator, recommended.


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#3 ·
Re: About to do a bunch of work to the bike; advice welcome!

CB, you just packed years of experience into a single post...thank you! As a bonus, my daughter is going to go APE over the dog picture. :D

Questions: Why do you recommend both the fz-1 and the ap-1? Are you running both? I know you have a ton of extra lights on your bird.

I did forget to mention that I'm seriously considering adding a voltmeter, rocker switches (for my headlight and something else I can't recall at the moment!), and usb ports to the left-hand plastic near the tank.

Also toying with the idea of converting to LED signals (with running lights in the front signals) and adding running lights to the rear signals (why are there never running lights back there???). Using a new flasher relay seems easiest to me rather than resistors.

Would like to also do a speedo healer, gear indicator, shift light, and blue led instrument lights...but ran out of money back at fork oil. :) So may leave these last things until next year.
 
#6 ·
Re: About to do a bunch of work to the bike; advice welcome!

...// I did forget to mention that I'm seriously considering adding a voltmeter, rocker switches (for my headlight and something else I can't recall at the moment!), and usb ports to the left-hand plastic near the tank.

Also toying with the idea of converting to LED signals (with running lights in the front signals) and adding running lights to the rear signals (why are there never running lights back there???). Using a new flasher relay seems easiest to me rather than resistors.

Would like to also do a speedo healer, gear indicator, shift light, and blue led instrument lights...but ran out of money back at fork oil. :) So may leave these last things until next year.
I can also only highly recommend installing a voltmeter... They come very cheap and might turn out to be an invaluable gadget!
I installed a USB-port under the instrument cluster, highly recommend the 'TAPP'-system from 3BRPowersports.com https://3brpowersports.com/products.php :thumb:
Also made the switch to LEDs and running lights in the front indicators, very happy with the result. Chose the HONDA CBR1100XX CLEAR SMOKED LED INDICATORS DRL DAYTIME RUNNING LIGHTS BLACKBIRD | eBay despite several other members expressing their concern with regards to the intensity of the yellow indicator when flashing... I find them quite sufficient, though!
Did the Gear indicator also - together with the voltmeter and LED-lights in the instrument panel... Not a need to have, but definitely nice to have!
Speedometer Gauge Auto part Measuring instrument Tool
Vehicle Gauge Speedometer Car Tachometer


Good luck with all your projects! :)
 
#4 ·
Re: About to do a bunch of work to the bike; advice welcome!

Question for anybody who can tell me:

When I replace the brake and clutch bleeder valves, is fluid going to squirt out? Or dribble out? Or come out at all? Never done this before...
 
#7 ·
Re: About to do a bunch of work to the bike; advice welcome!

Make a 1/2 inch wide paint stripe on the inside of the double bubble at the transition of the 2 bubbles. The refraction of the sun at the transition has been known to cook the gage cluster warping the housing.

Ohh forgot order a full set of fork bushings. If your pulling the tubes it will be good to have them in case you find worn out old ones.
 
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#8 ·
Re: About to do a bunch of work to the bike; advice welcome!

Doc, that looks sweet...but you realize you covered up the most used numbers on your speedometer with that gi, don't you? ?
 
#15 ·
Re: About to do a bunch of work to the bike; advice welcome!

Doc, that looks sweet...but you realize you covered up the most used numbers on your speedometer with that gi, don't you? 
Arent you worried you wont be able to read the gear indicator when the needle gets in the way at 320kph?


(EDIT: Damn, just noticed WildDoktor beat me to it)
Guys, you're absolutely correct... but then I suppose I can play ignorant in court?? "320km/h officer?? No, really that can't be - see, it can only go 300km/h, so your reading must be way off" :smilebig::cool:
 
#9 ·
Re: About to do a bunch of work to the bike; advice welcome!

WildDoctor, I have the ape 1, the other belongs to a friend who also has one on his ST1300. I just took a few picks as he installed grip heaters.


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#10 ·
Re: About to do a bunch of work to the bike; advice welcome!

I think some LEDs in the front turn signals and if possible the Givi turn signals as well. Installing the voltage indicator and GI in the dash is a great idea but way to tricky for me.


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#13 ·
Re: About to do a bunch of work to the bike; advice welcome!

Bach,

Simple but sometimes invaluable suggestion. Take pictures of everything. Digital space, unlike film, is cheap. Photograph everything and every step.
I agree, but please tell CanadianBird to photograph everything except the dog please !
 
#17 ·
Re: About to do a bunch of work to the bike; advice welcome!

Bach,



I agree, but please tell CanadianBird to photograph everything except the dog please !
Love digital[emoji106]



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#18 · (Edited)
Re: About to do a bunch of work to the bike; advice welcome!

Just stopped by my local Fastenall store at lunchtime and picked up my 80mm bar-end bolts. I ordered them because I read this page. Pretty sure this person is or was a member of this site? In either case...thank you, because I discovered I had the same issue with my throttlemiester bar ends.

Just as with the poster of that article, I called Fastenall and they got me a couple of these ordered and didn't even ask for my card, and when I went in there today the customer service was spot on. Pleased!
 
#20 ·
The Saga Begins!

Well, here we go!!

First, gotta setup a temp workstation with a keyboard/mouse that I don't care about so that I can look at the great tutorials and the service manual on this site with gloved/greasy fingers:

Computer desk Furniture Desktop computer Desk Technology


With that complete, I began by removing the fairings. Warning: half neked bird pics!

Vehicle Motor vehicle Automobile repair shop Motorcycle Car
Land vehicle Vehicle Car Motorcycle Automotive tire


My used PB Double Bubble arrived today! And yes; that's the kitchen cabinet I ripped out this evening. :D

Drum
Wood Plywood


Mmmm...Japanese Titanium Goodness!! Ready for cleaning. :) Purolator PureONE filter, PL14610.

Vehicle Auto part Motorcycle Motor vehicle Automotive tire
Auto part Exhaust system Engine Automotive exhaust Automotive exterior


Hmm...discovered a leak while taking pictures. I'll have to research and see what that is...may be buying a gasket.

Auto part Engine Automotive engine part Motorcycle accessories Vehicle


Sleep, work, repeat. More tomorrow!
 
#21 ·
Re: About to do a bunch of work to the bike; advice welcome!

any chance that the oil in the clutch will fall off? I am a bit afraid of removing that because of this reason.. I know the cover should be n easy job but did not expected to find the clutch slave there...
absolutely none unless you undo the hose banjo or the piston is leaking ..... and if they were leaking you wouldn't be concerned about the sprocket. Just remember not to pull on the clutch lever when the cover is removed since this will pop the piston out of the slave cylinder.
Thanks Duck; you helped me again! Cleaning crud out of my sprocket cover now; also cleaning the clutch rod. :D
 
#23 ·
Re: About to do a bunch of work to the bike; advice welcome!

Answered my own question: it's an OEM. I was told when I bought the bike that it had a K&N...guess not!
 
#24 ·
Re: About to do a bunch of work to the bike; advice welcome!

More surprises! This ain't gonna work...the angle of the banjo bolt end when the block is installed is wrong, and it won't twist. :-( Contacting convertibars since they supplies the Hel lines.

 
#51 ·
Re: About to do a bunch of work to the bike; advice welcome!

More surprises! This ain't gonna work...the angle of the banjo bolt end when the block is installed is wrong, and it won't twist. :-( Contacting convertibars since they supplies the Hel lines.

BTW, got this sorted. Steve from convertibars replied; all I needed to do was gently grab the housing above the banjo fitting with some pliers and twist the banjo fitting. Super easy, and he guarantees it won't leak. We'll see. :)
 
#25 ·
Re: About to do a bunch of work to the bike; advice welcome!

Stupid question question: there seems to be some sort of build up on the rear side of all the butterfly valves. Is this supposed to be there or should I clean it off?




 
#27 ·
Re: About to do a bunch of work to the bike; advice welcome!

Stupid question question: there seems to be some sort of build up on the rear side of all the butterfly valves. Is this supposed to be there or should I clean it off?
From what I've read it's a lubricant from the factory. Mine looked identical when I had her apart last week. I've seen posted it's best to leave it alone! -BIG DAN:thumb:
 
#26 · (Edited)
Re: About to do a bunch of work to the bike; advice welcome!

Just for grins, I'm live-streaming my garage via youtube. Come hang out with me until it gets awkward for me and I shut it down. :)

http://www.youtube.com/user/wilddoktor/live

ehhh....nevermind. Getting a bad connection and don't have time to fool with it. Maybe later!
 
#28 ·
Re: About to do a bunch of work to the bike; advice welcome!

Do not use carb cleaner on those throttle bodies. They have a coating on them and it will be taken off. You need special throttle body cleaner to clean them. Ask around the parts places for it or your Honda shop is better..
 
#29 ·
Re: About to do a bunch of work to the bike; advice welcome!

Thanks guys; i won't mess with it. I thought I'd better ask; all 4 looked *very* similar, as if they were done on purpose.
 
#30 ·
Re: About to do a bunch of work to the bike; advice welcome!

BTW, I've come to a stand-still. The two bolts that hold the reflector above the front left caliper are completely rounded out on the inside! I can't even tell if they are torx or allen, and can't find a picture on the parts fische at servicehonda.com. So now I have to figure out how to get these stupid things out! Ugh.
 
#32 ·
Re: About to do a bunch of work to the bike; advice welcome!

BTW, I've come to a stand-still. The two bolts that hold the reflector above the front left caliper are completely rounded out on the inside! I can't even tell if they are torx or allen, and can't find a picture on the parts fische at servicehonda.com. So now I have to figure out how to get these stupid things out! Ugh.
They should be allens. Chances are the PO used the wrong size and rounded them. They also have a built in flange. You can use a standard bolt and washer until you can order replacements. I'd recommend these guys
hondatoledoeast.com
 
#33 ·
Re: About to do a bunch of work to the bike; advice welcome!

Woo Hoo...back to work! Had a snack, cleared my head, prayed...MONKEY WRENCH!!

That's how I roll. :D

Bolts off, time to continue!
 
#34 ·
Re: About to do a bunch of work to the bike; advice welcome!

Ok, now the moment of truth: is there a way to tell if the forks have been "re-valved" in any way? It's obvious to me that the spring is now a longer-than-stock, linear spring (I was told it's 1.0 kg?), and the spacer is about half the length of the original (comparing to the terrible pictures in the manual). But...valving? I don't see any gold or red in there...is there another way to "valve" them? No biggie, just want to know what I have so I can update my sig. :D

 
#35 ·
Re: About to do a bunch of work to the bike; advice welcome!

I went hunting today! Killed, gutted, strung up to dry. :D



Done for the day. Time to eat, binge watch the last 6 episodes of the 3rd season of "Agents of S.H.I.E.L.D.", then hit the garage in the morning. [emoji3]
 
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