Man I wanted one of those REAL bad for a long time, never did find one cheap enough, it would've made the perfect garage mate to my VFR700FII. Looks like a cool project, post lots of pics as you go.
Me too ! But really nice find - where did you have it shipped form ? What kind of a PITA has it been to get parts , and I couldnt even imagine the costs, what with the dollar in the toilet --
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" Any book is a childrens book , if the kid can read !"
Mitch Hedburg
Getting the full treatment, 100% restoration, tearing it down to the last nut and bolt. Seller assumed the motor was seized, bike sat for a very long time, hence the flash rust in tank and overall corrosion. Bike actually has low miles 8500 KM or 5100 miles. Bought from Ozzie Saez at cycleimportsfl.com. He has been a gray market importer for 10-15 years. He has 3 buyers in Japan and fills up a shipping container with about 20 bikes. Customs has changed quite a bit lately so most of the bikes are for export only, but he does have some really nice stuff here in the US. Check him out. Thank you Flea-Bay, without you this could not be possible. Lots of parts in UK and Australia, some in the US. Yes, I will try to get the bike plated when it is complete. Have bill of sale and Japanese title. Numbers match. Anyway, I got the motor started and runs like a gem, clutch works, gears work, all is well. Will check valve clearances and compression, rebuild and re-jet carbs. Rebuild both master cylinders, rebuild forks and shock, powder coat wheels, triple clamps, possibly powder coat frame, maybe some parts anodized. Will repaint all bodywork and possibly the tank as well. Have spare upper to make into track fairing. Oil has been changed twice already after I ran the bike. Coolant flushed twice. All electrics in good working order, ran the bike on generator alone and it ran fine. RectumFrier is still good (weak link on these bikes), CDI good. Will derestrict speedo, easy fix. I hate to say it, I must be getting old, but I almost enjoy working on the bikes as much as I do riding them. Fun, fun, fun.
Heading to Lowes to get some rust remover solution, going home, filling the tank with nuts and bolts, adding the solution, and tumbling the tank over and over and see what surface rust can be removed from inside the tank. Then decide where to go from there. If it's real bad I'll have to get the tank dipped and that will remove the nice paint work on the outside. I don;t feel real comfortable with the epoxys and sealants. Who knows.
Ive had several of my project bike tanks sealed at a local radiator shop with great results- I know 2 bikes Ive had are still running and the sealer is in tack. Id check that alley out before destroying the pain, unless you are 100% on painting it, then it will just save a step !
Great job BTW - I know Im looking forwardto more pics !
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" Any book is a childrens book , if the kid can read !"
Mitch Hedburg
Busy day today, bike is ALMOST completely broken down. Just got stuck at the end on the large hub nut on the swingarm, 46mm! I'll either have to go and try to find a socket that size, or get a big F'n monkey wrench. Did the intial, but not final, cleaning and degreasing of everything. It is now officially a "bike in a box" or rather several boxes.
Mulitangle valve job, degree the cams and put some huge flat slide carbs on it !
JK - put it together and ride it !
Right now everything is completed broken down, labeled, bagged, tagged, and boxed up in the garage. "Bike in a Box" is what I like to call it.
I've thought about getting into the motor but.................
1)Aftermarket and replacement parts are all but non-existant (unobtanium).
2)If I screw something up..................refer to #1.
These motors if maintained properly are known to be virtually bullet proof. So why mess with a good thing to get a few more horsepower. Max I have seen on VFR/RVF400 race bikes is 72 hp. I've got the race can and I'll rejet and rebuild the carbs which should yield a few (ie: 1-2) hp but I'll be aiming for a bike that runs smooth and clean throughout. Going to rebuild the forks with Race Tech valves and springs. Rear shock is not rebuildable but is great shape so I'll try that initially. Have rear ride height shims ready to go. Can't drop the front because of limited clearance issues. Rebuilding front and rear master cylinders, CRG levers, doing something with the rear sets.??? Already have Renthal front and rear sprockets, 520 conversion. Found EBC HH brake pads on Flea Bay. Stainless lines front and back. Need to strip, sand, and repair all the body panels before paint. Still dealing with the rusty tank issue. Trying KBS Coatings tank kit this weekend. Have all new hoses and clamps. Going to clean and re-tape the wiring harness. This bike is really simple in design, not much to it compared to modern bikes. The entire electrical system includes the following, basic wiring harness (lights, guages)battery, generator connection, starter relay, rectifier, CDI, and ignition coils. That's it. Fuel system is the same, tank, fuel line, breather line, carbs, throttle cables, choke cable. No other connections. Clutch is cable operated, lever, cable, and actuator. It's amazing how much more is on Fuel Injected bikes. It's going to take the next 2 months to prepare everything for re-assembly. Everything, and I mean everything, will be cleaned, inspected, repaired, re-finished, and stored until then. Trying to work on a logical order for re-assembly in my mind. But I want to have everything ready to go and then it shouldn;t take long. Goal is to hit the track in late September. Ok, now where was I.....................................
Wow - I couldnt do it... ahhhhhhhhhh yes I could.... who am I kidding?
I understand your not wanting to do any engine work... but are you cracking her open and checking things internally? Or just trusting she is ready to go?
Wow - I couldnt do it... ahhhhhhhhhh yes I could.... who am I kidding?
I understand your not wanting to do any engine work... but are you cracking her open and checking things internally? Or just trusting she is ready to go?
Oh yeah! Track!!!
I'm going to do the top end. I have rocker cover gaskets and head gaskets ready to go. If all checks out well that's as far as I will dig. Definitely don;t want to crack open the cases.
Cut the rusty heat shield off the rear shock. These are the brake pads that came off the bike, almost like new! Nissin rear, Vesrah fronts. Calipers cleaned up beautiful. Rear spindle and hub assembly even more beautiful. Taped up the tank real good to prevent any of the harsh chemicals getting on the perfect paint, used a plumbers test plug to seal it up, right now some serious chemical reactions are going on inside that tank. We'll see how it turns out tomorrow when I seal it. I'm telling ya, this bike was like brand new, it just sat for about 10 years. Cheers!
'02 Honda 919 - She's the only one for me!
Awesome project, good luck.
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