Wrenching in a freezer

[criminaldesign]

I felt like the Donner Party, stuck in a cold garage with the bike on a lift.

I may be blowing it a bit out of hand a bit...

First off I have to give props to the torpedo heater and 15 gallons of kerosene. Without them none of this would have been bearable. Regardless of the temps it's fun, a learning experience and it's always a good time shuffling around the bike lift with Dad.

The digital camera proved very useful in documenting the job. Went back a number of times double checking items.

Started with the fork seals. Between the forks we replaced the 6 o-rings, 2 seals, and 2 piston rings.

We had to improvise our tools for the top cap without removing the bars. We trimmed down a bold and the head served as the allen wrench for the top cap. We were having the darndest time removing the top cap with this huge cresent wrench, too tedious. It dawned on me a BMX crank wrench may just do the job which I had. The wrench was slightly too small, nothing a grinder can't handle. Shaved off a bit of metal and the wrench worked.
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/od3DK0_ObutBmGKHJzTylQ?feat=embedwebsite"><img src="http://lh6.ggpht.com/_QUlLxCsQNp0/S0QadGyxI_I/AAAAAAAABTs/Z_E5QOqwZp4/s800/Fork%20Wrench.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

Next step we went on to rebuild the carbs.
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/MJBVmrbWgeK0vdGxbJjfJw?feat=embedwebsite"><img src="http://lh5.ggpht.com/_QUlLxCsQNp0/S0Qabl_aeGI/AAAAAAAABTo/U9wO0sSDeW0/s800/LeftCarb.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

Overall the carbs were in decent shape. Reused an o-ring as the kit was short. Between the two we found 2 dried out o-rings, the rest still felt good.

I replaced all the fuel and vacuum lines and the sleeves on the head and airbox.

While the top cover was off, I removed the starter to oil. This was tight. I took a 13M wrench and cut off the open end and shaved around the closed end so the wrench could fit a bit easier in the rear bolts.
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/HKotl9SFhcin8KjZEPHuUw?feat=embedwebsite"><img src="http://lh3.ggpht.com/_QUlLxCsQNp0/S0Qc2AVaoHI/AAAAAAAABUY/r-RwxtVVrTo/s800/StarterWrench.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

Starter removed:
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/ZjZ7FrKoiLHitBsYPxDMlA?feat=embedwebsite"><img src="http://lh5.ggpht.com/_QUlLxCsQNp0/S0QaX7LJWeI/AAAAAAAABTg/Y4T-uDN-yek/s800/Starter.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

Under the cover. Cleaned and oiled both ends
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/3UogpIkA14ij4pEgKPR1Bw?feat=embedwebsite"><img src="http://lh6.ggpht.com/_QUlLxCsQNp0/S0Qk13NG6GI/AAAAAAAABU8/_mNn7prsLmk/s800/StarterRear.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

Dad showing me how to test a starter:
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/3RWuPyKw3vu9HPaBC4_RMg?feat=embedwebsite"><img src="http://lh4.ggpht.com/_QUlLxCsQNp0/S0QaVzaI1_I/AAAAAAAABTc/uHCNjN0hVbY/s800/StarterTest.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

While putting back in the starter, go figure an allen wrench drops in the motor. We're definitely doing splines now.

First I had to remove the airbox.

Airbox, what a mess. the 13M bolt to the trans box is no biggie. It's the bolts behind the valves that you have to remove to remove the bolts.
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/F_OBsDSdSmXyDZj8ApgbYQ?feat=embedwebsite"><img src="http://lh3.ggpht.com/_QUlLxCsQNp0/S0QagGYCMQI/AAAAAAAABT0/dEJGOL6o8Lc/s800/Airbox.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

Wrench dropped right out. Splines were bone dry but looked in good shape. Cleaned and greased. Went to a honda dealer about the grease, mechanic gave us the best kind of grease, a free glop of grease.

<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/nvYH82jY5mdXq07QojfMWw?feat=embedwebsite"><img src="http://lh5.ggpht.com/_QUlLxCsQNp0/S0QaabV_PII/AAAAAAAABTk/x_cbU_SMLF4/s800/Splines.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

I just like this picture. Installed the Omega last year.
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/Sp84sTz8OlSHa78tjv2RmQ?feat=embedwebsite"><img src="http://lh5.ggpht.com/_QUlLxCsQNp0/S0QaekNGQII/AAAAAAAABTw/Sv4waTF-6gg/s800/Diode.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

Action shot.
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/dLv6P93UL0mlIZqoL23Tqg?feat=embedwebsite"><img src="http://lh3.ggpht.com/_QUlLxCsQNp0/S0QaShQIf0I/AAAAAAAABTU/PA1M3N78O9M/s800/Torn2.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

Bike back together.
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/XoCpdl0SGLBHxj1Jje7RFg?feat=embedwebsite"><img src="http://lh5.ggpht.com/_QUlLxCsQNp0/S0Qc4hk-aLI/AAAAAAAABUc/RAD0Y2BoXHs/s800/Complete.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/BikeMaintenance?feat=embedwebsite">Bike Maintenance</a></td></tr></table>

Also did routine maintenance on the bike, valves and lube. Filled with 10W 40 for the winter. Replaced all bulbs in the instrument cluster, been riding with a dark tach for awhile.

Next is balancing the carbs once there's a break in the weather.

Bikes been really good to me for the little over a year I've had it. I've put 31,000 miles on the bike, no problems on the road and you can do a majority of the work yourself.

Later guys, h

[beemerguru]

Looks like a great way to have some fun and get the bike ready for spring!! Spending time with Dad is always at the top of any list.

You didn't consider blocking or removing all the extraneous plumbing for the emmissions while you were in there?

Search for the past threads on how and why this might be a good thing for the heads and valves.

Just curious, did you oil the starter bearings or grease them ;-)

[crazydrummerdude]

Just remember to balance them when the bikes warm.

Good job!

[ccolwell]

I empathize on the cold garage; I'll be out in mine today. It's not too bad with the overhead forced air heater, but the tools and bike parts are still cold. In fact, I'll be posting a "identify this part" thread later today.

[criminaldesign]

You didn't consider blocking or removing all the extraneous plumbing for the emmissions while you were in there?

Plugged them up last year. It did cross my mind to remove them. May still yet.


Just curious, did you oil the starter bearings or grease them ;-)

Started with a dab of grease. We then threw power to the starter and added oil the bearings where it worked itself in.


I empathize on the cold garage; I'll be out in mine today. It's not too bad with the overhead forced air heater, but the tools and bike parts are still cold. In fact, I'll be posting a "identify this part" thread later today.

Haha, I know what you mean. The new fuel and vacuum lines were a bit more snug and didn't want to go on all the way. I would wave the lines around in front of the torpedo to warm up and expand and the hoses went on a lot more easier. Warmed up electrical tape and oil too by the heater.


Just remember to balance them when the bikes warm.

Yep. Once the snow on the road has cleared I'll ride the bike for 10 or 20 miles before balancing.

[mneblett]

Plugged them up last year. It did cross my mind to remove them. May still yet.
FWIW, if you do remove the pulse air compoents from the airbox: The rubber timing hole plugs fit the holes in the sides of the air box perfectly.

[kgadley01]

Sounds like you did a fine job. next time you want to do that much work in the middle of winter, bring it down to my place. I have a 30 x 30 insulated heated garage with lots of tools and beer....

[BubbaZanetti]

FWIW, if you do remove the pulse air compoents from the airbox: The rubber timing hole plugs fit the holes in the sides of the air box perfectly.

call up max's and say "removing pulse air" you'll get hooked up with the right items.

[88bmwJeff]

Glad to see you got some wrenching done. BTW, what did you decide to do about the exhaust threads? Oh, And by now the pulse system is probaly plugged anyway due to carbon build up (mine was), but I would remove the pulse system. It's a lot less crap to deal with on the bike.

[criminaldesign]

Glad to see you got some wrenching done. BTW, what did you decide to do about the exhaust threads? Oh, And by now the pulse system is probaly plugged anyway due to carbon build up (mine was), but I would remove the pulse system. It's a lot less crap to deal with on the bike.

Exhaust threads, that's the next bit to be addressed. I will go with the clamps you pointed out a while back. 38mm header pipes correct?
<table style="width:auto;"><tr><td><a href="http://picasaweb.google.com/lh/photo/KPVLgVemeOys-kZat_WnRA?feat=embedwebsite"><img src="http://lh3.ggpht.com/_QUlLxCsQNp0/SyleoSQ4E5I/AAAAAAAABP8/-oEJQraiBNY/s800/DSC_3592.jpg" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="http://picasaweb.google.com/houstonmcintyre/Random?feat=embedwebsite">Random</a></td></tr></table>

I am going to remove the pulse system just for that fact.

After all was said and done, I was putting the top cover back in place and found the airbox was to tight, making it impossible to put the top cover in place. So I had to remove everything again just to loosen the bolts. I have to say it's easier the second time around removing everything from the box.

I'm going to have to cut the pipe to the head. Seized up, which is why we just plugged it at the airbox end.

[jforgo]

Exhaust threads, that's the next bit to be addressed. I will go with the clamps you pointed out a while back. 38mm header pipes correct?

I am going to remove the pulse system just for that fact.

After all was said and done, I was putting the top cover back in place and found the airbox was to tight, making it impossible to put the top cover in place. So I had to remove everything again just to loosen the bolts. I have to say it's easier the second time around removing everything from the box.

I'm going to have to cut the pipe to the head. Seized up, which is why we just plugged it at the airbox end.

I have been filing the top covers in the lower rear area just enough to let them slip in and out without disturbing the airbox.

[BubbaZanetti]

I'm going to have to cut the pipe to the head. Seized up, which is why we just plugged it at the airbox end.

it's funny, snowbum mentions this is a big issue. mine came out nice and easy once i took the system apart and bent the pipes out straight.

[criminaldesign]

it's funny, snowbum mentions this is a big issue. mine came out nice and easy once i took the system apart and bent the pipes out straight.

I haven't tried them since we plugged the line.

I'll give it another go. Figure on firing up the bike and using a bit of Kroil in there.
Let the heat do its magic

[bogthebasher]

Loved the way you 'created' the right tools for the job. I am very familiar with doing this while working with my son on his turbo powered Toyota Celica GT4 stable. Shameless plugs follow:

http://gtfour.ca/

http://celicatech.com

Everytime you see the notation for that special Toyota tool ($$$$) you have to get creative and build one. I have ten or fifteen specifically re-purposed tools for doing various things. Good on yah.

[bogthebasher]

Meant to say to check out the 'Story' and 'Pictures' sections.

[squiffynimrod]

call up max's and say "removing pulse air" you'll get hooked up with the right items.

Bob's BMW calls it "EPA Kit" I think it was about $15 for just a few bits but an easy job.

[BubbaZanetti]

Bob's BMW calls it "EPA Kit" I think it was about $15 for just a few bits but an easy job.

i was trying to be a bit "on the dl" in my description as i'm not sure what dealers are allowed to say and what they aren't with supplying items for this kind of mod.

but basically, 2 F650 drain plugs, 2 copper washers and 2 timing plugs. make sure those plugs (both rubber in the airbox and screw in at the head) are in securely, you don't want to lose one.

[criminaldesign]

2 F650 drain plugs, 2 copper washers and 2 timing plugs. make sure those plugs (both rubber in the airbox and screw in at the head) are in securely, you don't want to lose one.

right on. thanks for the info bubba.

I wonder if pinching the pipe would be best since they already are securely in place?

I'm sure they would want you to keep it on the DL. If word got around that a dealer was supplying kits to dismantle emission rigs, I'm sure they could get a scolding.

Like asking a garage to knock out the catalytic convertor.

h