Newest family member = shed time

[dogsnbikes]

Last night we brought home the Latest member of the family:woohoo:

Melissa is stoked:yes:

for a $ a cc its a bargin and a good winter project

First job is too replace the fluids,plugs and filters and clean the carbs and fire her up,when they tried before it had all the marks of stale fuel and it had been siting for 2 years.......

Then it will be a complete frame strip down replacing bushes,seals,fuel lines,brake lines,oil lines and raditor hoses,wheel and steering head bearings,brake pads,tyres and drive train,

Rear suspension and front forks will also be getting and overhaul as well,

finishing with repainting and new decals and revinning......

we have allowed ourself a budget of $3500
and have so far spent $400 for 1 CBR400 areo

Time of completion labour weekend 2011

The benefits is that Melissa wants too learn too maintain her bike and what better way than too help in the rebuilding of the bike

the bike as it is now

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I will post progress reports during the rebuild:corn:

[YellowDog]

She's a beauty.

Great project plan.

Congrats to you.

Look forward to the progress photos.

[unstuck]

Nice project,great to see how it goes:woohoo:

[dogsnbikes]

Biggest plus is that Melissa wanted this bike as its just the right height for her ,and a good size for getting back into motorcycling after being out of it for a few years

[Owl]

Melissa is stoked:yes:

I bet!

Be great to see her riding her own bike. Great too that she wants to get into the maintenance side of it.:yes:

[dogsnbikes]

Well.......We started with the basic's today......removing farnings,replacing spark plugs and getting power too the bike

farings were easy enough...but spark-plugs were alittle bit tricky,considering I have KIWI mits and the bike was assembled by japanese mits.....Firstly I had too drop the radiator and lift the thermostat just too get into the plugs.....undoing the plugs was easy getting them out a bit of a challenge and was easly solved with a Long socket packed with axle grease,replacing the plugs called for a 8" length of garden hose placed over the new plug too help guide it into the thread.....

Next was sorting out the power to the bike...now the last owner had blowen the 30amp power fuse and had by-passed it with a 20amp tube fuse with a 10amp wire:facepalm:

Now a 30 amp doesn't blow for no reason,so replacing the 30 amp with a 30 amp would be a good start followed by connecting the battery......All lights go,things are looking up,starter motor works sweet,its like #5 is alive.....still waiting too see what cause the other fuse to blow....patience is a wonderful thing as it wasn't long before we started too see smoke......Bingo its a Faulty regulator-rectifier which will now be replace with a new one

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[yod]

nice to see you got the right brand

must pop over and have a nosey when i get a chance, hope Mel gets many happy miles out of it!

:niceone:

[86GSXR]

Very nice! :cool: :D

[chanceyy]

Orrrsommmee .. can not wait til Mel is mobile on two wheels :) .. :woohoo::shutup:

[dogsnbikes]

Well it was a total strip-down of the rear end today,it started by pulling of the sub-frame so I can get it ready for painting and it turned into a hell lets just get stuck in and get it all off.....and that is what I did....now the swingarm and suspension linkages are out and bearings removed which became a small issue as they were in tight they didn't want too budge:facepalm:,but with the help of some washers and a weilder and a fooken big hammer and punch they came out:woohoo:

Now I have the task of cleaning up all the parts for repainting and waiting for non stock parts too arrive....

The rear wheel has been striped and rotor has been measured.... its a fail so have too order a new one but I had alredy considered that in the begining along with new tyre,sprocket etc

so here is where we are at now I think the miss's will be somewhat shocked but at least I can save on tyre's if she is prepared too run behind her bike:innocent:

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[chanceyy]

I can save on tyre's if she is prepared too run behind her bike:innocent:



ohh Can I be there when you ask her that .. can hear her now .. B.. J... :finger:

[dogsnbikes]

ohh Can I be there when you ask her that .. can hear her now .. B.. J... :finger:

Your wrong she just laughed :bleh:

[chanceyy]

Your wrong she just laughed :bleh:



:doh: hmmm looks like we might have to :psst:
cause you know when we get together its a wee bit :devil2:



in realiity I thought her response would be .. :killingme

[ducatilover]

Very cool wee bike!!!! :love:

[dogsnbikes]

Very cool wee bike!!!! :love:

yes I wont be bored this winter,once I have all the parts I need for the rear-end I can knock it out in a arvo...in the meantime I will have too go back too work for more motorcycle token's:facepalm:

[ducatilover]

yes I wont be bored this winter,once I have all the parts I need for the rear-end I can knock it out in a arvo...in the meantime I will have too go back too work for more motorcycle token's:facepalm:
Makes me want to quit this pointless uni rubbish and restore the ZZR400K, Hagon shock, paint, anything perishable replaced with a fresh 600D motor and CBR/VTR Nissin front callipers!

[dogsnbikes]

Makes me want to quit this pointless uni rubbish and restore the ZZR400K, Hagon shock, paint, anything perishable replaced with a fresh 600D motor and CBR/VTR Nissin front callipers!

Haha...well the alloy swing arm is now polished and I am waiting on needle bearings and dust seals for the rear suspension....thats the problem with wanganui it takes longer too get the parts in than it does to do the actual job:facepalm:

[ducatilover]

Haha...well the alloy swing arm is now polished and I am waiting on needle bearings and dust seals for the rear suspension....thats the problem with wanganui it takes longer too get the parts in than it does to do the actual job:facepalm:
A bit like ordering bits from the states...and HK. The anticipation is massive! I can't wait to have the ZZR running and tuned, in the meantime I may pull the rear end apart and re-bush it etc. It's dirty in there (Being the arse of the bike....) and a spit/polish will make it pretty.
Oh and one of my chain tensioner bolts is munted....:facepalm:

[dogsnbikes]

Well things have been going well,after finally getting the last of the needle bearings on back order,the rear suspension is back together and sub frame attached.....

Last night we picked up a doner bike rather cheap but with a near new Battery and pirelli sport demon on the rear 17" wheel and near new rotors front and rear measuring 5mm(ours are 3mm) it was a bargin at $255 :banana: and has just put us months ahead in the rebuild process....and I also get alot of parts for the CB500 project double score :wari:

the donor bike

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Problem now is I have too head away for 2 weeks :weep: But I will have all the the new muffler and replecement tail farning pieces when I get back

So what too do with the remainder of the Donor bike?????it has been susgested that we could turn it into a trackday bike or we just sell what we dont need making it a even cheaper rebuild than first budgeted for......

Spending to date

CBR400 $400
Donor $255
Bearings,seals & paint $350
Muffler $100
fuel Tap $ 40
mirrors $ 50
Rear farnings $110
Air Filter $ 60
Oil Filter $ 18
Oil $ 50
Sparkplugs $ 20


Total $ 1453

[chanceyy]

Good Score Baz .. your shed must be getting pretty full with all dem bikes :)

[Icemaestro]

Where did you find both of these bikes? So cheap!

[ducatilover]

Bloody hell you're doing good! The ZZR600 owes me nearly $1700 now and I have to throw a new black rubber bit on the round thing at the back :weep:

[dogsnbikes]

Where did you find both of these bikes? So cheap!

Both on Tradme The 400@ Tangimona and the 250 @ Bulls,the guy wanted at least 400 for the 250 but hey he only had 150 reserve :brick: his lost my gain:lol:

[Icemaestro]

sweet...should keep an eye out myself then, I was looking for a cbr400 originally before going with the vfr...

If you don't mind me asking..why does the cbr250r there have dual front disks? didn't the mc19 (the single R) have a single front disk?

[dogsnbikes]

sweet...should keep an eye out myself then, I was looking for a cbr400 originally before going with the vfr...

If you don't mind me asking..why does the cbr250r there have dual front disks? didn't the mc19 (the single R) have a single front disk?

have too ask the engineer's that one,Maybe they thought they could save wait,I have a MC19 front end on a CB250rs frame just waiting to get the front disc as I am using a XR hub which is 4 bolt and it needs to be offset so the caliper clears the spokes I know EBC do them @400 each rotor lucky I only need 1

[dogsnbikes]

Good Score Baz .. your shed must be getting pretty full with all dem bikes :)

yes I get number 8 on saturday in Nelson :lol:


Bloody hell you're doing good! The ZZR600 owes me nearly $1700 now and I have to throw a new black rubber bit on the round thing at the back :weep:

Still have too do the front end yet but still have 2k in the kitty

[ducatilover]

sweet...should keep an eye out myself then, I was looking for a cbr400 originally before going with the vfr...

If you don't mind me asking..why does the cbr250r there have dual front disks? didn't the mc19 (the single R) have a single front disk?
MC17 brakes didn't stop as well as the 19, more efficient design, the 17 disks are small, the 22 was the best of the bunch.

[chanceyy]

yes I get number 8 on saturday in Nelson :lol:

hmm dunna be saying that too loud or Al may feel the need to purchase another one as well
:facepalm: :sweatdrop 8 :gob: .. you will need a bigger shed soon

[dogsnbikes]

hmm dunna be saying that too loud or Al may feel the need to purchase another one as well
:facepalm: :sweatdrop 8 :gob: .. you will need a bigger shed soon

there is still the lounge :2thumbsup.....

yip Al's machanic will love him :lol:

[chanceyy]

there is still the lounge :2thumbsup.....

yip Al's machanic will love him :lol:

lmfao .. true true on both counts :rofl: :blip:

[Owl]

there is still the lounge :2thumbsup.....

Don't forget to put newspaper down!:msn-wink:

[dogsnbikes]

This morning I decided too take alook at the doner bike as too the reason it wouldn't run.....simple really lack off fuel and the fault the fuel cock...

So after spraying the carbs with a decent amount of carb cleaner,them a decent amount of jumpstart and a decent battery,it burst into life and actually goes rather well with the typical 25year old honda cam chain rattle until it warms up...so now I have a running motor for sale and other 250 parts:innocent:

[ducatilover]

You'll make some moolah back from that :yes: Does it have the spring loaded tensioner on the back of the block? I also thought it would've been gear driven?

I'm treating my baby to maintenance this week :scooter: and some Pilot Powers. It now owes me $1750 I think :rockon:

You don't want any ZZR parts do ya :innocent:

[dogsnbikes]

You'll make some moolah back from that :yes: Does it have the spring loaded tensioner on the back of the block? I also thought it would've been gear driven?

I'm treating my baby to maintenance this week :scooter: and some Pilot Powers. It now owes me $1750 I think :rockon:

You don't want any ZZR parts do ya :innocent:

Already made the moolah on the parts that are going onto the 400 in savings mind you I just got the new Reg/rect so thats just increased out goings....

Now its getting serious as I will be stripping and sortings parts I am keeping and listing all unwanted parts which includes a full set of farnings........

[ducatilover]

You must have a hell of a garage....:blink:

[dogsnbikes]

yes but its a tidy version of hell:innocent:speaking of which I need too go make room for the XT550 thats arriving sometime this arvo...either I need less bikes or a bigger shed I perfer the latter of the 2:shutup:

[dogsnbikes]

Well I finally got around to hooking up the new Reg/rect this afternoon and some fresh fuel(flogg from another bike) hooked up the battery and starter and my trusty can off jumpstart,Now the moment off truth pushing the start button things sound promising ,some blow backs but mostly that sound of a motor wanting too start....

It wasn't long and I had a runner :woohoo: God it sounds great no cam chain rattle just a smooth running engine,Considering we had never herd the engine running when we got the bike and the fact that for two years the last owner couldn't get it too run.......so it was always a gamble and something that was in the back of the mind

so now things are cracking along a new set of radiator hose's have been ordered,and new fuel lines too be made up,strip and service all the brakes and comply,wheel bearings,new front tyre,service front forks and then start on the cosmetics...almost there now :drinkup:

[chanceyy]

Awesome :clap:

[blackdog]

Good job dude. Will she be getting custom or original paint?

[dogsnbikes]

Good job dude. Will she be getting custom or original paint?

Thanks...Melissa wants to go with a blue and white scheme as opposed too the red and white scheme....

[dogsnbikes]

Spending to date

CBR400 $400
Donor $255
Bearings,seals & paint $350
Muffler $100
fuel Tap $ 40
mirrors $ 50
Rear farnings $110
Air Filter $ 60
Oil Filter $ 18
Oil $ 50
Sparkplugs $ 20


Total $ 1453

What happened to the donor bike??

Well it was decided too sell parts that were'nt needed for the CBR400 build and the CB500 build..

Parts used on CBR400

battery.
Rear rim.
rear rotor.
rear tyre.
rear master cylinder.
Tank rubbers and mounting bolt's

parts keeping as spares

Headlight
front indicators
rear tail light/indicator unit
assorted bolts,nuts,washers and rubber gromets

Parts used on CB500

left hand switch block.
right hand switchblock/throttle
Front brake master cylinder
front brake lever
Clutch leaver
flasher unit
Ignition switch

Parts sold off CBR250(donor bike)

Engine package $350
Mirrors $ 20
headlight bracket $ 30
exhaust system $50
Rear hugger $25
Barends $10
Front calipers $80
Cockpit & front farnings $100
Side and tail farnings $100

So in reality this Bike is costing more in time than it is in money,

lucky my time is free

[ducatilover]

You're doing bloody well! Got pics?

[dogsnbikes]

Guy just been to pick up motor and sold him the header pipes and muffler for $50..its all going into a kids Gokart :facepalm:

will do more photo's next week

[ducatilover]

That'll be a fun go-kart though :yes: Neat, look forward to pics. You should do my ZZR up :innocent:

[dogsnbikes]

Well the coolient hose's arrived yesterday:woohoo:only too discover they were not for a CBR400Rg(Aero):facepalm:..

Oh well we can't control everything so back to the parts boy,with my old hoses in hand and MY parts catalog:innocent:No listings of these parts ever being in NZ so its a wait on the boat from Japan,so he is hoping they have then in stock there...

Other work completed the new Reg/rect is mounted too the bike and new leads made up to make up the short fall due to the Reg/rect being mounted in a different position..

The new wheel spacer has been turn up and wheel back on the bike....so am just waiting on front and rear sprockets too arrive now and ordering the brake kits to arrive next week along with the fork seals......

All the farnings are at the sign writers,so they can measure up and make a full set decals,Then its off too the plastic weilder before going too the painter.....I am using the same Tradesmen as I used when I did up the CBX750 Bold'or last year,their work speaks for itself
http://www.kiwibiker.co.nz/forums/showthread.php/127441-Finally-the-Bol-D-or-is-back

So there is no reason that the 400 won't look just as good if not better once its finished

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[ducatilover]

Shame about the pipes! Can't wait to see the end product though, will be uber nice :yes:

[dogsnbikes]

Shame about the pipes! Can't wait to see the end product though, will be uber nice :yes:

Well the bad news is now that all the pipes for the 400 are no longer avaliable:facepalm: well at least i dont have too wait for the boat from japan too arrive now....

as for the good news I have been able too sorce the hose needed too make new ones here in Wanganui:woohoo:

The sprocket set arrived today so the rear end of the bike is almost finished

[ducatilover]

I suppose that's even better in a way.


I may need to start parts hunting soon too :yes:

[dogsnbikes]

Well the work has started on this section,after pulling the wheel off and speedo unit it was discovered that the speedo cable had no inner....not too worry I still had the one of the CBR250 I just had too find it :facepalm:

Pulling the forks out and start to pull them apart I had problems with the criclips one was so stuck the ends broke off the clip and my pilers broke:angry:But we got there in the end....

After working out what size bearings and seals I needed,I went shopping for steering head bearing and seal kit,fork and dust seals,front wheel bearings and seals and a needle bearing for the anti dive on the front suspension...I am waiting for one front wheel dust seal now,but the wheels are going too the painters next week with the rest off the farnings and tank,so its not urgent

So for now I will have the forks back together and on the bike,new front leavers and hotgrips on by the weekend.

We did have a small hiccup with the sprocket set due too changing the 18" rear wheel too a 17" of a CBR250,the issue was that they don't make a front and rear match in the chain size use on the 400 so this was solved buy using a blank rear which I will have back from the engineer this week....

So I am almost finshed and have already decided on nexts winters project(unless I finish it before winter)

Things still too do
Strip and clean brake componants(I already have the kits)
Brake declaration
revinning
chain
new front tyre
fit wheels and farnings
and new muffler

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[yod]

Well the work has started on this section,after pulling the wheel off and speedo unit it was discovered that the speedo cable had no inner....not too morry I still had the one of the CBR250 I just had too find it :facepalm:

Pulling the forks out and start to pull them apart I had problems with the criclips one was so stuck the ends broke off the clip and my pilers broke:angry:But we got there in the end....

After working out what size bearings and seals I needed,I went shopping for steering head bearing and seal kit,fork and dust seals,front wheel bearings and seals and a needle bearing for the anti dive on the front suspension...I am waiting for one front wheel dust seal now,but the wheels are going too the painters next week with the rest off the farnings and tank,so its not urgent

So for now I will have the forks back together and on the bike,new front leavers and hotgrips on by the weekend.

We did have a small hiccup with the sprocket set due too changing the 18" rear wheel too a 17" of a CBR250,the issue was that they don't make a front and rear match in the chain size use on the 400 so this was solved buy using a blank rear which I will have back from the engineer this week....

So I am almost finshed and have already decided on nexts winters project(unless I finish it before winter)

Things still too do
Strip and clean brake componants(I already have the kits)
Brake declaration
revinning
chain
new front tyre
fit wheels and farnings
and new muffler

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nice.



have already decided on nexts winters project

which is...?

[dogsnbikes]

which is...?

finish the CBGB500 which by winter will be just cosmetic and electrical all engineering work should be completed by easter and start the XT550 rebuild..

[dogsnbikes]

Over the last couple of days and in between trips around the block,I have managed too get the new muffler mounted and flange sorted (old system was a I piece header pipes and muffler)and spruse up the header pipes,wire up the hot grips,Paint rear brake lite switch bracket that i made up a couple of months ago,secure radiator in position.
This morning I have dropt off all farnings,rims and tank too the painter so they should be finished with all new decals and clear coated,we are going with a white and blue theme(thats what the missus wants) when I get back at the end of the month,

So all very exciting and the missu's is getting nervous about getting on the bike as she dosen't want too stratch it when its finished :facepalm:

So now the bike looks like a suspended chassis

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[chanceyy]

ohh exciting its getting close to be finished .. woootttt woootttttt then that dodgy bytch will be on two wheels .. yay :)

ps if she wants to have a quite wee ride with the girls we will come & take really really good care of her :shutup::innocent::love:

[dogsnbikes]

Well deadline has come and gone and we still don't have a bike on the road....as said painted bits still at the painter nevermind as now I am thinking of pulling the engine out but at least the rolling chassis is sorted once painted bits come back too me...


Reason for engine too come out,well after doing a compression test these were the results

#1 130psi
#2 135psi
#3 95psi
#4 150psi

The bike wants too start but doesn't sound like all is well either.....Have had some backfiring through the carbs.........Maybe valve clearances are out but considering that 3 out of 4 plugs are really badly fouled,I am thinking something more is the problem..so its worth while pulling the head off and cheaking condition of valves,pistons and rings...considering the time and effort gone into the bike so far at least the engine will be sweet afterwards

considering we had engine running earlier in the year its a step backwards but the end result will be a better one


So will sort this out in the new year

[ducatilover]

Bugger mate, good luck getting the beast running!

[dogsnbikes]

Update

engine requires new rings and Valve seats are being done so its having a nice freshen up along with carbs overhaulled it should be a nice little runner, once we find a base gasket:rolleyes:

[ducatilover]

Would it be the same base gasket as the CB400 super four, or CB-1? They'd be readily available from the U.K

[dogsnbikes]

pretty sure its the same as the CB-1.....Oh spoke to the painter today all parts should be painted tomorrow,told him I will see him in two weeks:laugh:

The bike can wait, We are crossing the ditch on Monday for 8 days on the bike:bleh:

[ducatilover]

I'm sure it's the same early gear driven cam motor?
Neat! Have a good ride

[dogsnbikes]

Got some parts back this week,all the paint work is completed and the rest of the farings and tank are at the sign writers atm getting new decals made and installed...

The only parts that don't need decals
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Looking smart complete with a new set of Conti Go's
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Good news on the motor the rings,valve seals and head gasket have all turned up so its a matter of the engine being put back together..I was at the workshop today and bead blasted the outer engine casings,gear leaver and water pump casing so now they just need to be polised up

So there is nothing more I can do until I get back home after the 21'st

[dogsnbikes]

Well back into it and this morning bright and early I got the engine back and started putting the bike back together this afternoon

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so it didn't take me long to get it mounted back into the frame even managed to get a wof done,go shopping at tradezone,pick up the missus from work and get the lawns done:crazy:

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[dogsnbikes]

Almost finished now,just need a chain:crazy: bolt in screen and do the fluids and put tank decals on as tank was only picked up today and paint needs a couple of days to cure.....On that note folks MERRY XMAS TOO YEE ALL

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[ducatilover]

Looks excellent mate!

[blackdog]

Very nicely done! And the weather is playing ball for the maiden voyage too.

[Clivoris]

Top skills you obsessive bastard.

[Owl]

Looking good Barry!:D

[dogsnbikes]

Today I Picked up the chain put oil in the engine coolent in the radiator petrol in the tank and attached jumper leads,didn't take too long I am pleased too say and the ol'e gurl fire's up and she is sounding sweet so I guess I have done something right.......

Have ordered new blade/screen bolts,and going to make un an adapter plate too fit the new mirrors

but today was her first time out in the sun since we started the rebuild back in April 2 months over deadline but the wait was worth it and I am still under the orignal $3500 budget:wari:

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[chanceyy]

She looks awesome Baz, rather keen to have a closer look next weekend :)

btw hope you & Mel have an awesome day morrow :hug: to you both :)

[ynot slow]

Great project completed awesome finish,don't matter how long if under budget.

[NZsarge]

Today I Picked up the chain put oil in the engine coolent in the radiator petrol in the tank and attached jumper leads,didn't take too long I am pleased too say and the ol'e gurl fire's up and she is sounding sweet so I guess I have done something right.......

Have ordered new blade/screen bolts,and going to make un an adapter plate too fit the new mirrors

but today was her first time out in the sun since we started the rebuild back in April 2 months over deadline but the wait was worth it and I am still under the orignal $3500 budget:wari:



You've done extremely well with the bike Barry, as I don't check into KB as often as I used to I didn't even know you'd bought and been working on it, Mel must be wrapped with it..

[dogsnbikes]

The Mirrors arrived today and now the bike is finished and with it being Mel's birthday tomorrow everything has worked out well (yes I did get her a pressy as well) and booked in to be revinned on the 24th of next month:woohoo:

As for the budget to date It has cost $2850 so even with the cost of revinning we will still be below our orignal budget of $3500,now this has come too an end I can get back into the CB500 project come the new year:corn:

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[chanceyy]

wootttt woottttt Awesome good to see you can reach the ground Mel :)

fantastic job, she looks super dooper !!

[dogsnbikes]

Bike is now revinned :woohoo:

[chanceyy]

Bike is now revinned :woohoo:

woooooooooooooooo hoooooooooooooooooooooo yeeeeeeeeeeeeehaaaaaaaaaaaaaaaaaaaaa :clap: not that I had any doubts it would fly thru Baz with you pulling her apart & checking her all over :)