2002 919 - Project Skully2 - Salvage Rebuild - Wrist Twisters
 
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post #1 of 7 Old 11-12-2015, 12:58 PM Thread Starter
Tirone
 
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2002 919 - Project Skully2 - Salvage Rebuild

First off, my name is Nick, I have a shop in Reynoldsburg, OH called H3 Cycles. I typically work on late 80's classic cycles but I found this Honda 919 for $200 bucks. I couldn't pass that up. Besides, I really wanted a EFI street bike to ride. Mind you, I ride a v-twin cruiser that has carbs so this is a whole new world to me. I've done tune ups and some basic maintenance to EFI bikes but like I said the newest bike I worked on or owned was a 1986 Intruder 700. So... bear with me...

This is what I was told from the PO...
  1. Bike is in pieces
  2. Has been dropped on both sides
  3. It is in a lot of pieces
  4. Sat outside
  5. Very low compression
  6. Looks like a 2004 919 salvage engine
  7. Front mounts are broke off (from frame sliders)
  8. Said he wasn't getting power to the coils
I know that is a lot.


Here is the bike when I picked it up...





Then I got it home to do some inspection to it.

Broken front mounts from the sliders...




Well you can't ride anything without front engine mounts... so time to drop the engine...

Funny thing happened... I could get it out without using a persuader (rubber mallet) to beat off the air box. So, I'm in the market for one now...



I sent that down to a welder buddy of mine and he was able to TIG the mounts back together. I will be submitting more photos of that tonight. Cost me about $70 bucks for that. I need to grind them down and drill them out again but honestly it looks like that may have fixed it.

Things I have found so far...
  1. The oil is milky so either the block is cracked or the head gasket is blown - lets hope for the latter or that it sitting outside was the culprit
  2. The chain will probably need replaced
  3. The headlight mount assembly is shot but I have tons of material to fabricate something up
  4. The seat has a tear in it
So it looks like I have my work cut out for me. If anyone would like to subscribe and help me thought this project, I won't hesitate to make sure I help you all out when needed as well!

I must be crazy for taking on this project but for $200 I couldn't pass it up!

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post #2 of 7 Old 11-12-2015, 01:35 PM
(Quintus) Pilus Prior
 
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Yep, you're in for some fun! For future reference, removal of the airbox doesn't require a mallet....but a 3' prybar sure helped. I used a 2x4 to protect the valve cover.

Here's some photos from a rebuild I did.

https://photos.google.com/album/AF1Q...N_TuPHlLJgXCjG

Something tells me she sat outside, so wouldn't be surprised if water found its way in from the outside.

if you love your motorcycle, set it free.. if it comes back and hits you.. you highsided
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post #3 of 7 Old 11-12-2015, 01:48 PM Thread Starter
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I got a 404 Album not found on your rebuild photos.

When you drop the engine the air box has to come out though right? I was having a hell of a time finding any info about it. Also, the air box has a screw under the frame, no screw driver will find its way in there and the same thing on the screw that is recessed in the air box. Do all have a strategy for getting that one out before dropping the engine or does it all come down together?

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post #4 of 7 Old 11-12-2015, 02:49 PM
rmb
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Hello and welcome! Sounds like a great project, looking forward to seeing the progress!

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post #5 of 7 Old 11-13-2015, 07:02 AM Thread Starter
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Engine mounts welded in

Well $70 bucks later I've got material to mount to now. I need to grind them down a bit and make them a little more presentable but after a single drill out they should be good to go.








H3 Cycles - Reynoldsburg, OH 43068
Sticky side down...
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post #6 of 7 Old 11-13-2015, 11:49 AM
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Damn google! https://goo.gl/photos/zTii5wW9NgB4Xvv28 should work. Air box came out before the engine. I don't remember how I got to them, but I am certain I didn't break the air box to remove it. I'll have to push my 919 out later to refresh my memory of what you are talking about. I have several options for removing screws in hard to reach places, as I've fought with crap like this more than once so it may have just been a matter of tooling.

if you love your motorcycle, set it free.. if it comes back and hits you.. you highsided
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post #7 of 7 Old 11-22-2015, 06:17 PM
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Poor bike!

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