I'll be back-posting the full restoration of Scott's '82 Magna restoration here, then posting regular updates as the assembly phase starts in about a week.
Scott works for the same company my oldest brother worked for, not far away, in San Antonio. We got to chatting and he decided to ride his '82 Honda Magna 750 down to Laredo and have me "freshen it up"; he bought it new and he wants it to be returned to it's former shiny state after 50,000-plus fun miles.
We inventoried the bike from front to back, with Scott giving me his input as to what he wanted refurbished, what he wanted replaced, what he wanted polished or painted, etc., then I dropped Scott off at the bus station for his ride home.
I did a compression check and determined the top end was in excellent shape. Next, I drained all the fluids, and started disassembling the bike. Got the engine out of the chassis, pulled the rockerbox covers and clutch cover, and inspected all the wear parts; everything looked in excellent condition. So, this will be a refurb only, no overhaul; the engine bottom end will not be opened.
All new parts (gaskets, seals, camshain slippers, rubber bits, etc) are ordered and the last of them will be arriving soon. just a few back-orders (front brake pad set, u-joint rubber boot), I'll find the stuff somewhere.
Frame, swingarm, center & side stands, and bottom yoke all got powdercoated. Cruiser pegs, radiator front grille, and rear header shroud got re-chromed. 50+ pounds of parts are off to the polishers, and another 10+ pounds of hardware and small bits are off to be Cadmium plated.
Here's what it started out as, a bit tired looking, faded, tatty in the crooks and crannies, but well cared-for-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856915.jpg)
Once you start looking close, the little flaws show themselves. here are a few on the tank, besides minor scuffs and scrapes, it has a dimple up on the top/front, and a few chips on the top/rear...
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856920.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856925.jpg)
The seat was alittle more obvious, it'll be totally reupholstered with a memory foam top insert-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856928.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856931.jpg)
Let the teardown begin! This was last December...
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856934.jpg)
like to shoot pix of the various cluttered areas to re-route everything where it goes on re-assembly. The good thing is that the Honda shop manual has many illustrations specifically to show wiring, hose, tube and cable routing.
I believe these are all original locations...
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856938.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856944.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856950.jpg)
Rear wheel area-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856955.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857005.jpg)
Front wheel area-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856968.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856976.jpg)
The pix also make nice contrasts to the eventual "after" shots to see details that have been affected.
Engine area
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856960.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856999.jpg)
Headstock area-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856971.jpg)
One horn; Sabre has dual horns. Scott wants an aftermarket horn that's LOUD, so I'm going with a dual Fiamm kit with relay.
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856972.jpg)
Meters in good nick, speedo gets a new trip knob-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856974.jpg)
Storage area below the seat-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856975.jpg)
Radiator fins are in good shape, partly thanks to the chrome guard that'll get re-chromed-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856977.jpg)
carbs had been kitted some time back, but are gas stained. they'll get new gaskets & diaphragms-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856980.jpg)
Rear end shot-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857006.jpg)
Torn bootie and corrosion on the front brake line connection-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857010.jpg)
Handlebars & controls removed-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857014.jpg)
Coils & connections-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857015.jpg)
A shot down the intake tract, we're going with a new K&N permanent filter-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857017.jpg)
Chipped corner of the airbox will have to be fixed, although it's only cosmetic; the actual airbox interior has a second wall sealing off the filter chamber-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857020.jpg)
Torn bootie on the temperature sensor-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857023.jpg)
I'm not sure if these guys fell out from between the radiator and the grille, or if they were came and drank some coolant and it didn't agree with them...
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857025.jpg)
Radiator cap will either get replaced or at least the sticker-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857028.jpg)
Radiator removed-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857030.jpg)
That's a whole lot of sand in the downstream section of the airbox,-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857032.jpg)
The V-4 carbs are a bugger to get out, and a NIGHTMARE to re-install without snapping the very brittle fuel line "t" fittings between carbs. I had a custom fitting made from aluminum for my Interceptor-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857040.jpg)
A little bit of surface rust inside the headlight shell; it'll get knocked off and cold-galvanized-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857045.jpg)
Oops! missing a bolt on the exhaust collector on the underside-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857048.jpg)
Wiring harness removed; it's in good shape, no nicks or corroded fittings-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857049.jpg)
The bike is on a rapid weight-loss program!
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857053.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857054.jpg)
Milestone reached: engine extracted from chassis-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857063.jpg)
It's a heck of a lot of fiddling with teh bike stand to wiggle that engine out of there!
Now we can have a closer look at the engine-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857065.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857066.jpg)
Popped off the rockerbox cover to have a look-see-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857079.jpg)
Cams look okay, this is the worst one- seems to have some mild casting flaw pits-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857057.jpg)
Some typical wear, nothing excessive-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857060.jpg)
I have been told that there is nothing significant here as far as wear that would dictate a re-grind or new cams; anyone care to share?
Pulled the clutch cover off and found just a bit of dirty oil, no sludge build-up-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857080.jpg)
I did run across one broken cover bolt, looks like it had been drilled on to attempt to extract it, then was silcone'd in place-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857087.jpg)
Just a bit of crud and age-related oil hazing, no sludge and/or dark stains-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857086.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857083.jpg)
Flipped the engine over to get at the exhaust system; it's a real headache of an assembly with the V4 setup, the pipes grab the engine like ice tongs-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857088.jpg)
A bit of WD-40 and some elbow grease and I separated the exhaust system from the engine-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857089.jpg)
Back to the chassis - I had already stripped out the battery tray, electrical gear, lower gas tank & pump, coils, etc. Here, the rear wheel & shocks came off-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857068.jpg)
Removed lights, top yoke, meters, front fender, rider & passenger footpegs-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857070.jpg)
Front wheel & swingarm/gearbox removed-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857072.jpg)
Forks remove, after this shot, I also removed the centerstand.
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857074.jpg)
Steering bearings were kinda cruddy, they'll be replaced with the bottom seal-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857075.jpg)
Not many parts to be powdercoated, just the frame, removable tube section (also serves as a coolant tube), swingarm, centerstand, sidestand, and steering yoke-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857078.jpg)
Very few items to be chromed; radiator cover, cruiser pegs and rear header shield, that's it (everything else will polish out)-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857093.jpg)
A LOT more parts that have to get polished; forget it, I'm not going to type in the whole list!
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402857092.jpg)
I didn't get shots of the forks & rear gear teardown, but that all wound up around early March. Took me quite a while to sort out good sources for the new parts and get them all ordered, then a few HOT afternoons in the shop washing down all the parts to send them to powdercoat, polishing & chrome.
First time I've worked with "modern" forks where one has the internals for compression damping, and the other has internals for rebound damping. Kinda strange (in a good sort of way)...
Now we're caught up to early June.
Lazarus, COME FORTH!
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402858533.jpg)
Gotta love the shiny new stuff-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402858534.jpg)
...and don't forget the chrome!
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402858535.jpg)
Here are all the parts that will be Cadmium plated; I'm not going to list them all here, just posting the photos. Mainly fasteners, but a few bits & bobs that will look very nice when they're done.
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402891946.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402891942.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402891945.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402891943.jpg)
I got a bit of a scare this week; when I called to check on the parts at Cad plating, the lady told me they only received TWO boxes (I sent 2 boxes and a tube with 3 rods in it). As it would have to happen, I hadn't insured the tube (Scott's brake rod was in there with 2 of mine). Anyway, the tube arrived 2 days later, so all is well and Cad plated stuff should be here in about a week. Polished stuff will be here mid-week next week, so we'll just be waiting on the fasteners to get busy with assembly!
Lots of new parts including cables, gaskets, carb kits, footpeg rubbers, clutch plates & springs, rear brake shoes, rockerbox cover gaskets, oil filter, wiring & hose routing straps and camchain slipper pads-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402952024.jpg)
Sealed battery, wheel bearings, lower steering bearing, seals, o-rings, fork bushings, clutch & brake master cylinder overhaul kits, thermostat, starte brushes and miscellaneous rubber bits-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402952025.jpg)
Clutch cover gasket, alternator cover gasket, tank decals and sidecover decals-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402952023.jpg)
The two main items missing are the oil pan gasket and rubber boot for the driveshaft u-joint, the other small items are non-critical and won't hold up the rebuild.
Now mainly waiting on aluminum parts to get back from the polishers.
Don't you just love boxes of new parts?
Looking like an AMAZING project!!!! Seems like it would be a ton of fun, and the end result just awesome!!! Let us know how it turns out!
Lots more shiny parts - this time it's all the aluminum stuff back from polishing. Some of these parts still have to go through the paint shop to get the black areas refreshed...
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403180903.jpg)
looking good so far!!!!!
So, are you actually going to ride this bike? Or is going to a museum somewhere??
I'm sure Scott is going to ride the heck out of this bike.
for what it's worth:
I STILL cant do anything significant.
UPS claims to have delivered my big box of cad plated hardware, but my surveillance video cameras show the truck driving past my driveway down the road, then returning and leaving 8 minutes later WITHOUT ever entering my property.
I was here all day, working in the shop and my office, NEVER SAW HIM.
I'd sure like to know where that box is, supposedly the driver will be here today and "prove" he left the box.
Thankfully, honest neighbors showed up with my box yesterday mid-morning. I told them I'd take them fishing in my family's pond next weekend as a way of saying thanx.
"3204 Frost" (instead of 3304)
42 pounds of stuff, from 5 different projects in-work, plus spare parts-
(http://pic20.picturetrail.com/VOL1461/6266009/23504316/403252069.jpg)
To get a good idea as to the size of this pile, note the relative size of several coil clamps in the pile...
Okay, these should be in the same order as they went out (pix a couple of posts back):
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403259195.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403259196.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403259194.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403259193.jpg)
Just like new!
Hello Paul: I just got back in town last night from a week of vacation with family in Costa Rica; interesting to be in a place surrounded by motorcycles at every turn. Down there they are primary transportation in a land of $6/gal of gas and many poor roads. Mostly 250cc class enduro types, Japanese and Chinese brands. Watching them lane split everywhere and negotiate pot holes and pedestrians/animals in the road I came to appreciate their riding skills. Glad to see you have sucessfully made it into the MOOT world. And I'm glad all the parts made it to your door....they look great and I'm sure anxious to head you way and touch a few!
A bit 'o progress today, dropped by the painter's place to take him the key to the gas cap so they could finish prepping for paint-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403268839.jpg)
They're working on all the parts that take a Black patch-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403268843.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403268846.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403268849.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403268851.jpg)
Assembly starts in earnest after the 4th...
You've heard the expression "pictures don't do it justice"? Well, that applies here...
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403293291.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403293290.jpg)
This one ALMOST captures the true color; an EXACT match to the original color underneath the decals-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403293294.jpg)
The rest of the stuff, just as nice!
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403293293.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403293292.jpg)
When did you start this project for Scott?
How many bikes do you have?
Are you retired as in no real paying job? :P
Quote from: TLRam1 on July 04, 2012, 11:30:13 PM
When did you start this project for Scott?
How many bikes do you have?
Are you retired as in no real paying job? :P
Started in the fall last year.
Currently have 36 bikes in the collection (including basket cases / projects)
Retired? Yeah, right; with a 6-year-old and 1-1/2 year-old. I WISH I was retired, we were "that close" about 7 years ago...
Prime corner of the shop cleared away and basic components set to begin assembly-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403301965.jpg)
The plan is to start with the swingarm & rear shocks, then the forks, then wheels & handlebars to get to a rolling chassis.
Well, no joy on locating a new u-joint bootie...
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403533515.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403533516.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403533518.jpg)
So, on to drastic measures-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403533519.jpg)
Until today, I had no idea that Rust-O-Leum made a spray-on rubber adhesive.
This part is not under a lot of stress, it's mainly to keep grunt out of the u-joint; so, this ought to do the job. I just wish it was a smoother finish, maybe I can smooth it some after it cures.
Scott will be here Thursday to help get the bike to rolling chassis stage.
Preparing for Scott's visit to help me get started on assembly, here's the rear end parts-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403554570.jpg)
Front end parts-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403554571.jpg)
...and more front end parts-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403554572.jpg)
Scott rolled up the driveway at mid-morning and we got started on the front end. Immediately encountered a little resistance with the lower yoke bearing, so put that off and got on with the forks. Good thing I scanned and printed a copy of the assembly illustration, it took three attempts and a cut finger to get the anti-dive fork together, the other one was a piece of cake.
We then broke for lunch, and on the way home dropped in at my neighbor's shop and employed his press and a section of tube to slip the bearing in place. Not complete (on the front end), but at least a good start-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403554574.jpg)
Then it was on the the rear end where insertion of the pinion shaft into it's roller bearing took numerous attempts before we hit gold. After that, the locking ring nipped right up and I secured it with a dab of loctite on the retaining clip bolt-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403554575.jpg)
Slipped the pivot lugs in place and that's it for today (it's hot out here)-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403554569.jpg)
Scott is wheeling back up I35, a bit happier than when he arrived.
That is going to be one SWEET Magna when you are done :cool: :cool: Love the pictures also.
Love it! Keep us updated. Also mind sharing a list of all the bikes in your collection? Sounds awesome!
I may have shared my collection list in my intro thread...
Triumphs are my "long suit", and Bonnevilles are my favorites: 64 Bonneville street tracker rolling project, 65 Bonnie project on the shelf, 66 Bonnie chopper/bobber rolling project, all original 66 and restored 67 Bonnies, 68 Bonnie project on the shelf, 69 scratch-built Bonneville vintage roadracer, 69 mildly modified Bonnie street tracker, 70 Bonnie with TR6 scrambler pipes, my late friend's 70 TR6 vintage roadracer project, '71 Bonnie trike, all original '79 Special, and a rare unmolested '83 "TSS" 8-valve, triple disc, e-start 750. A couple of Trident 750 triples, a 74 & e-start 75. One modern Triumph, a 2000 legend 900 triple.
My latest big project is a '66 "TriTon" which is a Triumph Bonneville engine ("Tri") in a legendary Norton Featherbed frame ("Ton"). There are probably no two TriTons alike, mine has a Suzuki GT550 front end, famous for the 4-leading-shoe front brake; it's also got lots of MAP Cycle go-fast stuff in the engine, including alloy big bore kit & belt drive primary.
I've got a '72 Norton 750 Combat Commando cafe racer with some Dunstall parts, and an all original '75 Interstate 850 e-start. 1967 BSA Spitfire Mark II project on the shelf, and a '67 BSA 441 Victor thumper (the one with the easily recognizable alloy tank with yellow scalloped paint). Lastly, a '72 Rickman / Montesa 250 vintage MX in near original shape (front fender, carb & shocks are replacements). That's pretty much all the BritBike collection.
Other Euro bikes are a '72 BMW R60/5 cafe racer project and a '74 Moto Guzzi 850 Eldorado with a sidecar for the kids & grandkids.
I've had a lot of Hondas over the years, mainly Fours, but now I'm down to a '67 CL77 305 Scrambler (refurbished), my late kid brother's all original '82 CB750F SuperSport, and a lightly modified '83 VF750F Interceptor (there's my kinship to you lot). Turns out AHRMA (vintage racing assn) is introducing a new class in 2013 that will let me get the Interceptor on the track!
I've got a couple of classic Kawasakis - a 1980 KZ1000, stock except for a quarter fairing & headers, and a '71 H1 500 triple, legendary blue-smoker that can easily wheelie on throttle alone. I also have an '03 ZRX 1200R, my newest bike, which I salvage built from an insurance "total" wreck. Actually, it's my third ZRX salvage build.
Yamahas are getting slim in my collection, actually the two 2-strokers I have in my garage have already been given to my older sons. One is a '67 YDS3 250 GP replica bike with a full fairing, clip-ons, rearsets and expansion chambers, the other is a mostly original '76 RD400 with flat slide carbs & expansion chambers.
Rounding out the collection are a pair of very similar bikes that use the same Sachs 125 single engines: a '69 Penton 125 Six-Day Enduro "steel tank", totally original but old & tatty; and a bit nicer '70 DKW desert sled with leading-link style forks.
I believe that about covers it...
Quote from: grandpaul on August 04, 2012, 09:38:48 AM
mine has a Suzuki GT550 front end, famous for the 4-leading-shoe front brake;
You are probably talking the 72 GT750 4-leading shoe front end, I think in 73 the bike had disk. The GT550 has disk brakes and the T500 has shoe brakes but only on one side.
BTW, the 4-leading shoe rim/brake assembly is worth money.
Most people that are familiar with the Suzi 4 shoe believe only the 750 had them, however the 550 also had them in 72. The model was called the "Indy".
I did not realized it was a 4LS system in the first part of 72.
Nice TeaKettle, by the way...
Thanks.
Fork seals & u-joint bootie (e-bay score) arrived yesterday.
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403617104.jpg)
So, a little paint on the gear drive plastic rim and the rolling chassis will be complete.
Upholsterer finished the seat today - fantastic work.
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403617109.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403617114.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/403617121.jpg)
Back-tracking and posting up progress...
Engine stripped, washed & masked for painting-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403916735.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403916737.jpg)
Painted-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403916740.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403916741.jpg)
Significant milestone: Rolling chassis!
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403913683.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403913685.jpg)
Next, the marriage...
Clutch plates replaced, springs checked, etc.-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928931.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928932.jpg)
Detailed sections of engine-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928926.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928928.jpg)
Spiffy clean detailed engine, right side-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928933.jpg)
Left side-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928936.jpg)
Even the bottom is detailed-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928929.jpg)
I'll touch up the four bottom case fins after the engine is done being moved around and installed...
Do you, frame, take this engine...?
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928938.jpg)
"I DO"
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928939.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403928923.jpg)
Another milestone: engine/frame marriage complete.
A few detail before/after comparisons (before on left, after on right)
Engine bay-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403936463.jpg)
Lower gas tank & regulator/rectifier-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403936419.jpg)
Clutch slave cylinder / water pump area-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403936406.jpg)
A few more detail comparisons-
Battery tray / coolant overflow tank area-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403936395.jpg)
Underseat angle view of same area-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403936417.jpg)
Rear fender underside (stripped and coated with Rust-O-Leum cold galvanizing spray)-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403936416.jpg)
I like these engine comparisons, quite a difference...
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403936408.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/403936407.jpg)
:shock: :shock: :cool: :cool: :cool: Man awesome job that is going to be the cleanest Magna on the face of the earth when you are done.
Maybe not THE cleanest, but "it'll do till something else comes along"!
That is fantastic. You'd never shut me up if I had those kind of skills.
It's been a LONG week! Working to finally move to Austin, took a couple of big steps to solidify plans.
Meanwhile, got two major systems complete: carburetors & airbox, and radiator & cooling system components, hoses, etc.
Carbs are similar to any other CV units, EXCEPT when it comes to joining them back up in the intertwined "W" formation! So, I took a photo of the linkage arrangement before tearing them all apart; also labeled carb bodies, slides & floats-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017429.jpg)
Turns out the previous carb overhaul was a good one, they were quite clean inside-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017431.jpg)
Of course, it never hurts to go through them from top to botom, just in case. As it happens, the inlet screens were not replaced, and two of the low speed jets were slightly clogged. So, into 2 buckets of Berryman's Chem-Dip they went-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017435.jpg)
Some parts to be hand cleaned (chrome tops, slides, floats & choke plungers), plus the new carb kits-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017436.jpg)
Washed parts, rinsed, blast dried & ready for assembly-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017438.jpg)
Initial assembly done, now to align all the linkages & insert the super-fiddly syncronizing & thrust springs!
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017439.jpg)
This took a good bit of time, ended up installing the lower half of the airbox to better align everything, then inserted the springs.
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017440.jpg)
Carbs are an EXTREME bugger to re-install, had to install the 2 right side rubber boots onto the engine, 2 left side boots onto the carbs, then wiggle the cluster into position, then wedge forward 2 carbs fully home, then wrangle rear 2 carbs slowly down while working the boots with a thin screwdriver sort of like a shoehorn (sprayed with WD40)-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017445.jpg)
The "old" filter is a very nice UNI, in good shape. So, wash, dry & re-use-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017443.jpg)
Headaches done with, popped the UNI filter in and nipped everything up.
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017444.jpg)
Radiator painted, fan removed, cleaned, and replaced-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017447.jpg)
New thermostat-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017448.jpg)
Radiator mounted with re-chromed front guard & original radiator cap with "patina"-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017450.jpg)
Coolant hoses all done. The outer spring cover actually looks decent in daylight, the camera flash brings out a bit of corrosion. It's a bugger to paint springs where they look good, I may give it a whirl; probably have to set up a jig that hold the spring expanded, paint & let dry-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404017427.jpg)
For as tidy as this bike looked when Scott rode it up my driveway, it sure is grimy in the nooks and crannies!
Front brake caliper (R)-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404039344.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404039345.jpg)
Left side appears it's been toasted, and the pistons were well and truly varnished in place-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404039346.jpg)
Brake master cylinder (clutch looked about the same)-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404039347.jpg)
Had to drill one cover screw heads off to open it, then had to drill one clamp bolt head off, and then drill and re-thread it when the stump wouldn't budge and snapped clean off.
Shiny clean pistons-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404039348.jpg)
Bare caliper and master cylinder bodies are at the painters, will have 'em back on Thursday.
Picking up some steam on bolting on the various bits & bobs:
Radiator & airbox trim bits, rider & passenger pegs (with new rubbers), shifter linkage with new rubber booties on the linkage joints & shifter), rear brake pedal & linkage, plastic engine cover over the clutch slave cylinder (and clutch hydraulic line)-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404062574.jpg)
Front fender before & after de-rust and cold galvanizing the underside-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404062576.jpg)
Front turn signals refurbished & installed. Headlight cleaned & polished, cold galvanized inside, and installed; 'before' photo was posted during the teardown-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404062575.jpg)
Instrument cluster isn't too bad off, just very dusty and the aluminum cups are dull-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404062577.jpg)
For some reason, the tach cup was really scaled & dirty, speedo cup was relatively cleaner than this-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404062578.jpg)
Here you can see the significant difference between dull & polished, even though the bike photos pre-teardown looked pretty decent from 10 feet away...
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404062579.jpg)
At the rate it took to polish half of the bottom of one cup, it's going to take me all morning to polish both cups fully. THAT is why I typically send out all my polishing work!
By golly, it's almost recognizable!
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404062581.jpg)
Rear fender and front brake caliper mounts with new rubber grommets for the caliper floater bolts done.
Revised time log estimate puts it at 5 more days if I squeeze in as much as I got done today. Just in time for Scott to be able to shake it out and get in a couple of days of debugging if necessary before hitting the road for Barber's Vintage Festival in Birmingham. I believe this bike will turn a few heads at the VJMCC show.
I beleive your right the bike should diffently turn some heads it looks fantastic.
Long day, lots got done.
Finished up the instrument cluster, but waiting on a replacement speedo (much more affordable than a rebuild to fix broken trip reset shaft). Hmmmmm... didn't take a close-up of the finished cluster. Oh well, here are the polished & coated (inside) cups-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404073905.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404073906.jpg)
Cleaned, re-taped and installed the wiring harness, then connected 90% of the electrical bits including the starter solenoid, turn signals, headlight, instruments, thumbswitches, sensors, and coils ('before') photo in the disassembly phase near the beginning)-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404073916.jpg)
I had won an original exhaust system on e-bay that LOOKED decent, it arrived this morning and it had rust-through on the bottom; went back and looked at the e-bay listing and realized he hadn't posted any photos of the bottom!
Oh well, took some 0000 steel wool to the pipes and cleaned them up, then sprayed the collector box with high temp black Rust-O-Leum; looks pretty good-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404073907.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404073910.jpg)
I'll tell you, re-installing the rear exhaust pipes & heat shield is a real nightmare! I'm guessing aftermarket headers don't come with the heat shield. 3 hour's work just on the exaust-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404073913.jpg)
License plate bracket was rusty underneath-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404084954.jpg)
Stripped & sprayed with Rust-O-Leum metallic silver-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404084956.jpg)
Rear end done-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404084958.jpg)
Gotta love the MOOT patch - "Take the LONG Way Home"!
Rear section wiring done-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404084957.jpg)
Mid-section wiring done, fuel lines done, gas tank connection in place-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404084959.jpg)
New battery serviced with fresh acid, and taking a trickle charge-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404084961.jpg)
"Go for the Gold"
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404084962.jpg)
I know, I know, it's not a V-Twin!
Trying to troubleshoot fuel pump not pumping; meanwhile, setup a thin funnel and connected it to the main fuel line-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404084963.jpg)
VROOM! VROOM!
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404084964.jpg)
That's a major milestone at just over 106 shop hours to this point.
One small coolant leak, blinker wiring needs straightening out, and need to get the fuel pump sorted. Otherwise almost done. Painter has the brake calipers and master cylinders (brake & clutch) done, need to go collect them...
Just back from the painter's, it looks like tomorrow is "brake and clutch" day...
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404085258.jpg)
Your doing one hell of a job on it. I can't wait to see the finished product. If you can take a video of it starting up with a circle check of the bike.
I've not had good success with video, seems like a 20-second video is 20 megabytes and never can get them to upload...
First brake caliper partially re-assembled-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404115269.jpg)
The pistons are buggers to get in past the first new double-lipped seal; even bigger bugger (say that fast three times) is inserting the floating shaft and it's two rubber booties into the caliper mounting lug! I figured out the trick - lightly grease and insert one bootie in place in it's groove, install one bootie on the shaft, then slip it out of it's groove far enough to be able to work the larger outer lip into it's place in the other caliper mount groove, then push it fully home (not easy, as it's a VERY tight squeeze to get it in and past the lips of the 1st and 2nd bootie). This probably doesn't make sense unless you have the parts in front of you and try it.
Both calipers done, with all the little dust booties replaced on the carriers-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404115270.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404115276.jpg)
Front Brake & Clutch master cylinders done-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404115271.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404115274.jpg)
No suprises, no drama, just like new.
Now waiting for UPS to show up with the new braided stainless brake lines...
Got a few items checked off the list, it's almost down to just the two operational issues - coolant leak & fuel pump.
Sidestand and rear brake springs installed, replacement speedo, mirrors & cruiser pegs installed, new horns set up, just need to wire them into a new relay. Front brake line splitter installed, just waiting on the new brake hoses & grips now.
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404116480.jpg)
New speedo will necessitate a mileage differential note in the shop manual-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404116483.jpg)
Quote from: grandpaul on October 01, 2012, 03:31:43 PM
I've been following your process with great interest and enjoying the great detail photos as you move along. Thank you!
If I can ask one question: I'm unfamiliar with the brake setup in the below photo... what is the dial near the bottom left with the numbers 1, 2, 3, 4.... it looks like there is a type of trunnion assembly?
Thank you... and keep up the great work. It is obvious there is a lot of focus going into this effort!
Hop Along
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404115270.jpg)
Quote from: hop along on October 01, 2012, 07:05:15 PM
If I can ask one question: I'm unfamiliar with the brake setup in the below photo... what is the dial near the bottom left with the numbers 1, 2, 3, 4.... it looks like there is a type of trunnion assembly?
That's the braking anti-dive mechanism. Very ingenious, the upper caliper mount is free rotating, and the lower pivot allows a miniscule amount of fore-aft travel to exert pressure on the anti-dive plunger, causing it to restrict the compression damping as the bike starts to dive under braking forces. The rig is adjustable for rider weight and preference/feel.
! Got it! Thanks for the description! I just read about such a thing in a motorcycle magazine... maybe Rider or Cycle World, forget which. Now it all fits in my head and makes sense :-P
Pictures CAN be worth many words...
Thank you,
Hop Along
All that's remaining is the front brake lines and a set of grips; brake lines should be here tomorrow, I'm going to install a temporary set of grips so Scott can choose whatever he prefers.
So close...
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404128743.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404128740.jpg)
One thing for sure, those dual Fiamm horns BLAST OUT!!!
A little "before & after" comparison-
(http://pic20.picturetrail.com/VOL1461/6266009/24129095/402856915.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404128743.jpg)
Well, its a good thing you showed us the intervening pictures -- I would have bet money they were not possibly the same bike.
Good work.
That thing is gorgeous. Great job.
Handy location for the new horn relay with in-line fuse (just above the battery)-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404137941.jpg)
New starter button made from an old horn button, trimmed, drilled & JB-Welded in place-
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404137948.jpg)
I painted out the little horn icon and yellow line, just need to run to Wally World and get some white model paint to draw the little circular arrow. (or is it supposed to be red?)
WOW just awesome great job and plenty of pics :cool: :cool: :cool: :cool:
You did an amazing job on the bike restoration. It's to pretty to ride.
FINALLY got in the brake hoses (slow truck from Canada), and got the system filled & bled; it sure helps to have the brake bleeder pump kit.
The set of braided stainless hoses also came with the 2 pieces for the clutch as well. Nice.
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404164131.jpg)
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404164135.jpg)
Did a 15 mile shake-down and had only three issues:
-weepage from the front brake master cylinder cover; should be good now that I've tightened the screws carefully
-shifter range incorrect, I've already adjusted that.
-horn stopped honking; I must have pulled a wire loose when I was stuffing the headlight back in, it's all good now.
(http://pic20.picturetrail.com/VOL1461/6266009/24166894/404164096.jpg)
That wraps up this one!
Beauty shots to follow...
100 miles out on it's maiden voyage (Cowpoke's BBQ in Pearsall, TX), Scott is happy; the bike is happy except perhaps a bit of bleeding needed on the clutch, it gets mushy when the bike is on an incline.
(http://pic20.picturetrail.com/VOL1461/6266009/23504316/404196802.jpg)
Scott will be prepping for his 2,000+ mile trip to Birmingham, AL in a day or so; my guess is he's probably got some kind of windscreen / windshield / fairing installed by now...
(That's a Shoei quarter fairing on my '00 Triumph Legend 900 triple, I like the additional hand protection in a very small, sporty fairing)
Awesome bike!!! I hope she runs as good as she looks!!!!
You did an awesome job on it. It looks like it just came out of the crate. You can tell by the smile he is very pleased with the bike.
Well, Scott wasn't so pleased a day after that photo - one of the BRAND NEW, "HIGH QUALITY" braided stainless clutch hose fittings FAILED (leaked). So the bike stayed in the garage and he took his V-Strom to Barber. Huge disappointment all the way around.
That sucks. But at least he was able to put some miles on it. Give yourself a big pat on the back you did good. Even with brand new bikes fresh out of the box can have problems. A bad crimp on a line is minor. Considering the amount of work you did on it. Still can not beleive you have not put it away into a museum some were.
Quote from: grandpaul on October 15, 2012, 08:49:39 AM
Well, Scott wasn't so pleased a day after that photo - one of the BRAND NEW, "HIGH QUALITY" braided stainless clutch hose fittings FAILED (leaked). So the bike stayed in the garage and he took his V-Strom to Barber. Huge disappointment all the way around.
Perfection is elusive, but you came very close. Annoying, but minor, in the overall project. Congratulations on a great job.