"Roxanne's" Stripping For Winter [Archive]

RiderInBlack

11th May 2005, 18:43

Well having had a coolant leak since my March SI trip and an annoying cam chain rattle since Ruapuna, I have decided it is time to give "Roxanne" the big strip. I notice yesterday the coolant leak appears to be coming from between the block and the crankshaft housing (go figure:confused: ). This means the I will have to strip the engine to replace the gasket, so while I'm at it I might as well get the valves reseated, check the pistons and rings, and do the camchain and tensioner while she is in bits. Plan to do most of the work meself (can not afford the shop bill to do all this at the moment). Have stripped an old XA Falcon and a Mark2 Cortina down to get their blocks rebored and have reassembled them. Both servived and run fine afterwards. I have the Haynes workshop manual for a Honda CBR1000FL, but you will hear me swearing and cussing a bit as work on. Expect a few stupid and/or curly question being as I try to work it all out. Any recommendations will be appreciated (bar buying another bike, because I an't got the money for that:finger: ).

PS: This means that I won't be out on rides until I'm done:doh:

RiderInBlack

12th May 2005, 14:07

MSTRS

12th May 2005, 14:23

Rebuild or replace? Pros & cons to both. If replacement has a decent guarantee, I'd say go that way. You will at least have a shitload of spares. However, if you strip & rebuild you will know what you got & have learned shitloads..
Your choice RIB

vifferman

12th May 2005, 14:29

The cam chain I'll need as it was not replaced when the tensioner was replaced at about 33000miles, and I am getting a rattle. Should the tensioner and chain be replaced as a pair?
Yeah, it would pay to.
Might also pay to convert the tensioner to a manual one (in fact, you can get an APE one for less than a Honda one).

RiderInBlack

12th May 2005, 20:03

If she needs the ring and piston sets are there better proformance ones I should look at for the CBR1000F or should I stay standard? What are the advantages and disadvantages?

RiderInBlack

14th May 2005, 12:51

Well having had a coolant leak since my March SI trip.... I notice yesterday the coolant leak appears to be coming from between the block and the crankshaft housing (go figure:confused: ).My how removing fairrings changes how a bike looks:whistle: The coolant leak that I thought was between the block and the crankcase, is actually between the head and the block (had marked the leak when I spotted it but didn't get a clear look with the pieces for plastic in the road:wait: ). This makes a lot more sence. Hope the head is not warped. How can the head be checked for warping?

XP@

17th May 2005, 09:39

Roxanne's done about 52000Miles (about 84000Km). Don't know if she'll need the ring and piston set but?? The cam chain I'll need as it was not replaced when the tensioner was replaced at about 33000miles, and I am getting a rattle. Should the tensioner and chain be replaced as a pair? Gaskets I'll need to get rid of the coolant leak. Would it be easier and cheaper to replace the whole motor with a low Km one from the Wreckers?
We cheated a little with the gaskets, on the 600, they cleaned up nicely so we just sprayed them with gasket spray and on the first running, they seem to be ok (all the oil was pouring out of the rocker cover)
we decided that it would be better to try that approach first as it saved a couple of hundred bucks... if it failed then just need to strip the engine again...

RiderInBlack

29th May 2005, 09:59

Well at this stage the job list is just growing. Latest delemer is pitting on the forks. Not much but seeing I have "Roxanne" in bits and was going to repaint the fork housing, I better deal to it. I was going to 2-pot paint the fork housings as stripping them so they could be Powder-coated seemed too much hassle. As the forks are pitted I'm not got to waste the money on them as they will get replaced sometime in the near future. It the meantime I thought some temp. repair would do until I can afford replacement. Remember read some where in KB about sanding back a filling with epoxy. Could someone give me the heads up on that.

Other work being done on Roxanne:
Powder Coating both Rims and the Clutch Cover Plate (Metropolis Blue), and the Swing Arm (which is steel, Polish Alloy).

Value reseating.
New rings for pistons (the bores are good and still have some of the orginal machining marks).
Head and Block checking for level (releveling if needed).
New gasket for the up engine to be fitted.
New Camchain and tensioner to be fitted. Have look at spitting the crankcase to remone and fit the Camchain, but have put it in the too hard basket. Planet Honda have offer to split the new Camchain, fit it in the crankcase for me and rejoin it . Is this good practice? How will this effect the durability of the new Camchain?

And the list goes on.

RiderInBlack

29th May 2005, 11:15

Ps check for pits in the crome on the inside of the leg otherwise you will need to do it all again. Them pit can be just tiny (rub down with fine wet/dry paper
wash with sprit,fill with araldite and rud down If the pits are at the travel end think about adjusting the damping to keep away from the pit under brakes
so long as you dont mind harder suspension.
You can recrome the Legs if your rich :kick: :kick:And This

I used crystal Araldite 5 min set but fully make sure the mix is correct.the grit was the finest they had cant recall but if it scratches the crome its too course.
dont be impatient either try to get the araldite to only fill with little excess and leave for two days before you attack it.
Throughly clean the pit first with white spirt or nail varnish remover (ask the mrs). not turps or petrol, they are oil based and will act as a barrier to the glue.It worked for me but also consider the compression damping stop point, its rare to have pits below the compression line so if you stiffen it a tad you might avoid the pit all together?
This do for a year or two while I refinance after all the other work and then replace the forks?

RiderInBlack

3rd June 2005, 18:41

Talking to Greg at Planet Honda today. "Roxanne's" head was ever so slighty out so this, plus the fact Honda use a plastic/rubber coated steel gasket between the alloy head and block (doh), may be the cause of her coolant leak. Head and Block are being releveled. Valve and valve seat have been done. Gaskets and piston rings have arrived. Waiting for cam chain and tensioner, plus a set of piston pin circlips (should have ordered those with the piston rings, hey).

The fork houseings are looking good repainted el cheapo with VHT Flat Black in a can with a clear coat over top. Have sanded the pits on the fork arm, cleaned with brake cleaner and have applied the Araldite. Will now wait a few days for that to harden fully before sanding smooth. I am thinking abouty useing 10 weight fork oil instead of the standard 5 weight normal used for this bike to see if I can make the forks stiffer (they are not adjustables.

Short term list for "Roxanne":
Tide her up and get her back together, having fixed the coolant leak and cam chain rattle. The rims, clutch cover and swing arm are being power coated. Forks tided and fork oil replaced. Need to ether repair the exhaust collector box again or get some old pipe works from the wreckers (I don't think I will have any money left to get stainless ones do at this stage).
Hope to have this done in time for the next Rust Nut GC:niceone:

Long term wish list for "Roxanne":
Fibre Glass Fairings painted Black (with blue flecks) with a progressive yellow to orange to black lightening bolt (like in the thimb nail below).

Full Stainless Steel exhaust system.

Replace suspension system with full adjustable one (ether WP or Ohins).

Bonez

4th June 2005, 09:10

And This

This do for a year or two while I refinance after all the other work and then replace the forks?Ever considered fork gaiters?

Antallica

4th June 2005, 09:52

When was the last time you rode your steed brother?

RiderInBlack

4th June 2005, 16:10

When was the last time you rode your steed brother?That would be riding escort for The Three SC Cabarliros (Jantar, Blackbird and Mangell6). Good ride that. Have had her in bits not long after that, but having a look at the weather and road condition at the moment, I'm in no hurry to put her back together yet:cold:. The longer I take the more I will be able to afford what I'm doing, and the better job I will do of it. As long as I have her back together and running smooth in time for the next Rust Nuts GC, I'll be more than happy.

If you ever want a look at what her insides are like, this is a good time for it. Cann't wait to see how the rims, and bits look like after they have been Powder Coated.

By the way, I still have your Zoo Buscuits (UN-EATTEN what's more) waiting for the next time I see you guys:wait: I've nearly given in to the temptation on more than one occation, so I don't know how much longer they will last:whistle:

Are fork gaiters those ugly plastic things on the ag bike forks that look like NovaFlow pipe, Bonez?

Antallica

4th June 2005, 20:17

We thought those biscuits had perished in your belly!

We shall come for them, maybe next weekend when we have the cage.

XP@

5th June 2005, 08:56

That would be riding escort for The Three SC Cabarliros (Jantar, Blackbird and Mangell6). Good ride that. Have had her in bits not long after that, but having a look at the weather and road condition at the moment, I'm in no hurry to put her back together yet:cold:. The longer I take the more I will be able to afford what I'm doing, and the better job I will do of it. As long as I have her back together and running smooth in time for the next Rust Nuts GC, I'll be more than happy.

If you ever want a look at what her insides are like, this is a good time for it. Cann't wait to see how the rims, and bits look like after they have been Powder Coated.

By the way, I still have your Zoo Buscuits (UN-EATTEN what's more) waiting for the next time I see you guys:wait: I've nearly given in to the temptation on more than one occation, so I don't know how much longer they will last:whistle:

Are fork gaiters those ugly plastic things on the ag bike forks that look like NovaFlow pipe, Bonez?

Will be good to see her on the GC!
Don't know what I will be riding on it yet... depends on how well the CBR sells :)

RiderInBlack

18th June 2005, 21:43

Got the Swingarm, Wheel Rims and Clutch Cover Plate back today from ProCoat. They have done an awesome job:Punk: Bit tight putting the bearings back into the Swingarm, but have got it back on now. Will refit the rims and plate tomorrow.

Question for the Mec's here. If I have put new rings in the pistons but have not needed a rebore, have had a very slight bit taken off the head to relevel it, will I need to have the carbies retuned?? If so what would you recommend as to the best way to have this done?? I will nee to take the bike to Custom Chambers after I put her back together as the whole pipeworks is rotten and the cans have been rattling for quite sometime:whistle: I an think of getting the exuast system done in S/S and then getting ProCoat to do a ceramic powder coat inside and out. Would look at retuning then.

RiderInBlack

19th June 2005, 14:08

Note to self:

If the item that is to be bead blasted and powdercoated has threads, make sure thatyou have the right thread tap as you may find the threads need retapping:whistle:

Luck for me the home workshop had the right tap (8mm metric). It's the only metric tap we have here but (bloody lucky). I when to put the discs back on the front rim and found that the most of the retaining allen key bolts would not start properly. This was most likely due to some of the powdercoat getting in the thread holes, but could have been thread damage due to the thread not being protected when it was bead blasted (although I would think that ProCoat would have protected the thread). Carefully started the tap with my fingers before useing the tap handel. You have to be very careful doing this otherwise you end up cross-threading the old thread instead of just cleaning it (personally I find it much esaier to cut a new thread than clead an old damaged one, especially when you are dealling with aluminium).

RiderInBlack

24th June 2005, 19:14

Well nearly all her bits. They found a spit in 1 of the 4 inlet boots that join the Carbs to the head. Replacements are coming from Japperland. 1 has arrive but there are 3 more to come.
Must take so pic's of her all in bits before putting her back together. REALLY should have taken pic's as I was stripping her (bit kinky but) to remind my where everything went:doh:
Now comes the hard part, putting her back together right:whistle:
Have the Haynes Manual for her, plus Greg (Head Mech from Planet Honda) has given me a copy of head and block part of the Honda workshop manual even though I didn't ask for it. Thanks Greg:Punk:
Greg has been helpful and patient with me giving this a go. Have got him to do the bits I dare not attempt. Like:
Removing and setting the values.
Checking the head and block for level. The head was a little out and got set to get releveled.
Checking the old and new rings for fit and refitting the pistons into the block. The block got sent to get honed for the new rings.
Splitting the new Camchain and feeding it into the Crankcase.
Have got all my parts through Planet Honda so I have a fair bit to pay them. Some of my moo-la should get to Greg's pay packet (so it should, he's work hard for it).

Have told myself that I'm not allowed to start putting back together until I've finnished my tax return:puke: If I didn't I'd be down the road as soon as I could get her back together with the end results of Aunty Helen's Goons taking too much interest in my business:wait: :whistle:

RiderInBlack

28th June 2005, 21:15

Who else does a good job on pipes up here? Staintune does not make S/S pipeworks for the CBR1000F anymore (they stopped making them 2 years ago). New from Honda NZ standard (not S/S) pipework cost over $2000. I could import this from UK for about $1000 (150 pound for the pipes + frieght + duty + GST). I would still have to get 2 new cans as well. 1 after market can can set me back $500. I need 2! That's comes to around $2000 for the whole system, so if you know someone that can be trusted to do this work, I would really like to know them.
I think Custom Chambers said that they would make the pipeworks plus the 2 cans for around $2000. I will need to check that before mid-July as that is when I should have "Rox" ready for them. Custom Chambers needs my bike to make the pipe fit properly. Will Neptune or Cyclworks need the same? Where are they? I live in Whg so where I send "Rox" should be not further then Hamilton.
Do Cycleworks or Neptune make S/S pipeworks (I know they make cans)? I need the whole exhaust system from the outlet on the engine throught to and encluding the cans.

Really need help on this,

Doug

riffer

28th June 2005, 22:42

I've seen a number of early 80s bikes like KZ1000, GSX1100 at Cycleworks with the full exhaust being done to them, so I'd say they do it.

Give Damon a call.

BTW great to read about your mission. I look forward to seeing pics of the finished product.

badlieutenant

28th June 2005, 23:16

Im assuming your forks are the basic honda type (front)
Ive been thru a drama of fiddling with oil levels, preloads and oil types. If you ever fiqure out a way where all the manufacturers have a universal grading for fork oil let me know. I found thier were 10s and thier were 10s. And in the end the best oil Ive found was motul (at least for my old honda) sold as a heavy duty oil for older cartridge style forks. And it doesnt seem to have gone off like the others did.
Cheap option for rebuild of a standard honda rear shock - give this chap a ring gouden gizler (probably sp there) his number 09 236 9023. For $215 he rebuilt mine (including a vavle so that it can be regassed easily) and it works better than the new honda one I had. Just be sure and tell him what type of riding you intend doing, two up or single hardout he'll set it up for you (and how much you wiegh)

badlieutenant

28th June 2005, 23:20

RiderInBlack

29th June 2005, 19:45

RiderInBlack

6th July 2005, 21:28

Yep, slowly putting her back together now.

$2400 for engine parts and labour being paid to Planet Honda.
$226 for Powder Coating paid to Pro-Coat.
Still have $1600 to $2000 I'll need to pay to get new pipes and cans. Estimate from Custom Chambers goes as follows:
$600 per S/S can. I'll need 2 so thats $1200.
$400 - $600 for the pipes using steel for the 4 extactor pipes, going to a S/S collector with the standard 4 into 1 and out to 2 set-up.
Will get Pro Coat to ceramic coat these.

I've put the cams, camchain and camchain tensioner back in. Had fun getting the cams set right. Instruction went:
"Turn the crankshafty counterclockwise and align the index mark on rotor with the "T" mark on the crankcase."
Sweet ease enough. Look down at the the rotor and find 2 "index marks" on the rotor a mere mm or 2 apart:no: Which fu*king mark dudes? Talked to Planet Honda (PH) and found that they would have had the same problem. Greg (Head Mac @ PH) said the best bet was to find TDC for piston 4 using a rod going through an old spark plug and down into 4. Well there wasn't much difference between these 2 marks using that method, so I opted for the mark that was on the outter edge of the rotor (the other one was in a mm from the edge). Followed the book from there:Punk: I'll know if I've got it right when I try starting her again:whistle:

Set the valve clearances. Had to alter a 10mm spanner for that (just as well we have more than one. Glad we have a gas torch in our workshop:devil2: Had to put some new bends in the spanner to get it to reach the valve lock nuts.
Put the cylinder head back on. Borrowed PH's 3-Bond sealant for that (thinks guy's).

Still have some bits to put back on the "Rox's" "heart" before putting it back into her chest.

Slow and steady and I'll make less mistakes. Have learnt now that it is better to stop if I'm getting frustrated than to carry on when working with motors. I do less damage that way. Would beleave that I learn that one for reading "Zen And The Art Of Motorbike Maintance ( even though that's not what the book is mainly about)!

Thanks Ron (Pritch008):Punk:

John

6th July 2005, 21:50

Wow great news sounds like its getting back to its beast form!
Good on you for attacking the engine, cam alignment is so confusing - timing and all these crazy sprockets and numbers, I failed 5th form maths so anything more complexed that 1x1 really starts to stump me :)..

Cant wait to see it when its done :D (common! give us some pictures!)

RiderInBlack

6th July 2005, 22:21

Cant wait to see it when its done :D (common! give us some pictures!)She's still a bit "naked" at the moment:no:

John

6th July 2005, 22:35

wow, looks like your having alot of fun :lol: keep up the good work :D..

RiderInBlack

7th July 2005, 20:08

Used to floods here. Thats why the house is on top of a hill. River come up but has not broke the banks as yet. It been good weather for getting "Roxanne" put back together (cann't shoe horses or help Pa on the farm in this):Punk:
Have got her heart back into her chest but haven't got the carbs in yet. Hoping I won't have to do much to the carbs as they have been balanced before by the shop. It will be a big learning curve for me if I have to rebalance them before she will start. Have charged her battery and have a heavy duty 12volt battery charged up on stand by to give her a little boost to get her going again. Still a bit to do yet, but I just cann't wait to here her motor running again.
Once she's back together, I'll take her to Custom Chambers to get the exaust system done. Then it will be shake down time to make sure she's upto doing Rustnuts' GC this year.

Doug

RiderInBlack

9th July 2005, 18:36

God it was good to hear her breath again:Punk:

Still have a coolant leak but:no: It's around where the coolant pipes joint. I'll have to strip that part tomorrow. Hope it is just a split in the coolant pipe and not the jointer (or anything else expendsive and hard to get).

John

10th July 2005, 04:30

Wow cool, hope you can sort that leak asap - sounds good abit loud ;) but yes I think those carbies are happy :D

RiderInBlack

10th July 2005, 15:09

That's because I started her up without the cans on:devil2:

Sorted the coolant leak. Found a split to the coolant hose going across the motor. Yes this could have been the orginal leak, but I had to get her head off to deal to the camchain. On that note the rattle has gone:Punk: As for the coolant hose, ripped into Whangarei (40Km from here) and got a cage one that was a near fit (well 1mm bigger Diameter but at least the major bend was it the right place and it was long enough). Fitted that and there is no more leak.
Have a sticky throttle, which I think is due to cable placement and tension.
Still have to put the forks back in (have decided not to change the fork oil at this time but have grade10 fork oil here if I do), front wheel on and dress her again before I can ride her, so I might not get a ride today (but should be ready for a shake down during the week).

RiderInBlack

10th July 2005, 21:44

Fixed the sticky throttle, just the cables not quite in the right place.
Forks are on. Just need to dress her and put the cans back on.
If it rains any day this week I'll ride her down to AK for Custom Chambers to work on. The trick will be getting back home:whistle: Might be able to twist Dad's arm or I could hire a suitable trailer to load her on. Not taking the risk of getting her up on the Ute's flat deck as I have written off one bike already that way:wait:

RiderInBlack

11th July 2005, 22:31

Well "Roxanne" is all back together and has her dress back on thanks to all the rain we have been getting:devil2:
So have nothing better to do, seeing it was still raining, I took her to the movies (hey I hadn't taken her out of a while so she deserved a treat:devil2: ).
She purred along nicely, and I got wet :whistle: Still enjoyed it but:ride:
Pull into Ant & Jess's to see how they are. Seems the bandit is over due for some work too. Ant has not had it out since the Bowls Night in AK:no:
At Ant's request I gave "Rox" some rev's when I when I pass John's place to encourage him to get his bike working again too:whistle:
Then "Rox" and I went to see The Fantastic Four. Funny thing is they would not let her into the theatre:weird: so she had to wait outside for me.
The F4 was ok but not what I would have called Fantastic, but as an old Mavel reader I still enjoyed seeing Old Ben doing some clobbering.
Rode "Rox" home in misty night (I know, romantic aren't it:love: ,but blood glad that I took the Fog City viszer with me).
All going well, just need to get her down to AK and get my butt back up here somehow:confused: Might need some help with that. A spare driver or a low loading trailer would help (not kean to put her up on the flat deck as I have written off one bike that way:whistle: ).

RiderInBlack

25th July 2005, 21:03

Well I've had a long but good weekend. Took "Roxanne" down to Taupo for Pilgrim's 60th Birthdau party (a old biker mate, yep HD and all).
Had fun with some diseal on Bynderwyn's (fu*ken spill all the way down the South side:mad:). Lucky for me it was easy to spot due to some light rain giving it the lovely rainbow colours, so rode with caution and handled it well.
"Roxanne's" running well. Still running her back in. Not that you would have noticed on Sat when I linked up with Zed, LB and the boys down the 16:whistle: Enjoyed seeing and riding with you dudes again:ride: :Punk:Old Fart's 500 was going well.
Meet WT, Death and Draco at the Pap Autobarn. WT gave us a wheelie salute as he headed backup the motorway:whistle:
Made a donation to Labour's campain. I was going through an out of the way place with a very short 70kph zone and failed to slow quickly enough for my mate just around the corner from the 70kph sign:whistle: 90kph in a 70 zone:nono: He appoliged for not getting me for more, because he was a bit slow turning the radar on. I appoliged for not braking harder to counter that:wait: (hey I was cold and not thinking as quick as I needed to be).
Party was good. Bed sometime after 2am. Up by 8am on the Sunday. Back on the road by 9.30am (best thing for a hang-over). Dropped "Roxanne" of in Mangatawhiri, where the Custom Chamber dude lives. Yep it's always a good idea to ride a road bike up a wet muddy farm track after a long ride with a hang-over:rofl: Didn't drop her but so it was all good. They dropped me off at Bombay/Puke Service Station and I caught the bus back to Whangarei from there.

Have told the The Custom Chamber Dude not to hurry. He reckon's she'll be ready in less than 2weeks which would be sweet by me.

oldfart

26th July 2005, 19:36

Good tu meet ya RiderInBlack - enjoyed the suirt down SH16 :ride:

RiderInBlack

4th August 2005, 20:31

Well it's another bus trip for me tomorrow. Off to the really Big Smoke (AK) to pick up "Roxanne" from Custom Chambers. Hope the Pipes and Can are looking and sounding grand as it is costing me $1900:
$600 for each S/S Can (2 of these)
$550 for the extactors and S/S collector box (4-into 1-and out to 2 Pipes)
$150 for the silver ceramic powder coat.

Antallica

5th August 2005, 07:06

Have a good drive/ride brother,

I'll come stop by when Psychotron is ready.

RiderInBlack

17th September 2005, 19:12

Found an ad in the T&E advertising a Full CBR1000F Fairrring for sale. Rung the dude yesterday, and he said it was Black and Red from a 1991 CBR1000F. Went down to AK to look at it today. Man, it is nearly in mint condition bar the odd crack. With the fairrings I have been given a matching tank and seat. All the light housings and indicator are on the fairrings too. Will pick it all up tomorrow with the ute.

There is some work to do to them before I can dress "Roxanne" in Black so you will not get to see her in it until later this year.

Ooh, by the way, he also has a 1991 CBR1000F motor for sale; as well as forks, steering head, swingarm, brakes and rims to match if anyone is looking for some.

RiderInBlack

18th September 2005, 20:14

Found an ad in the T&E advertising a Full CBR1000F Fairrring for sale. Rung the dude yesterday, and he said it was Black and Red from a 1991 CBR1000F. Went down to AK to look at it today. Man, it is nearly in mint condition bar the odd crack. With the fairrings I have been given a matching tank and seat. All the light housings and indicator are on the fairrings too. Will pick it all up tomorrow with the ute.$300 for all that (includes a blade, tank and sissy bar). Man, did I score:wari: A 2nd hand tank from the wreckers for "Roxanne" cost me $250 alone last year. A replacement Blade $250. Side fairrings for the VFR cost me $360.
Have wash all the fairrings down. A few more cracks than I saw in my first look, but still less than I have repaired in "Rox's" old "Skirt".
Need to think up a colour scheme as there is a little too much red on the black at the moment. Would like something black with a lightening bolt through it and somehow tie in my blue rims with it. Anyone good with Pimping??