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Project Bike Thread: 81 GS650GL & 87 CBR600F

Articles, Essays, Reviews, Road Diaries, and your chance go Gonzo with your own weekly column. Be sure to read the FAQ before posting an article.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Mon May 03, 2021 4:26 am

I printed the first official bike part, besides the cramp buster, a set of license plate brackets! I did a test run in PLA filament, which is not suitable for automotive or long term UV exposure. These were made with PETG which is like ABS but without the harmful VOCs and fumes.
brackets.PNG
PXL_20210503_122141747.jpg
I plan on printing the headlight ears, and possible a new gauge cluster out of this same material but maybe in the radioactive green/yellow for funsies.
PXL_20210328_224415205.jpg
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Mon May 03, 2021 12:35 pm

OringsAndMore just got back to me about the water pump. They have 2 different items that may work. Since they're all under a buck, I ordered a few spares for future use. They ship super fast too.

https://www.oringsandmore.com/

*crosses fingers* Come on universe, grant me a trip to DooM 2021!
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Wed May 12, 2021 7:33 am

I decided to make some tank badges!
PXL_20210510_201702251.jpg
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Fri May 14, 2021 4:42 pm

Should they be bigger?
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by Jaeger » Fri May 14, 2021 10:08 pm

red wrote:
Fri May 14, 2021 4:42 pm
Should they be bigger?

PXL_20210514_193236700.jpg
No, those look right to me.

--Jaeger
Bigshankhank wrote:The world is a fucking wreck, but there is still sunshine in some places. Go outside and look for it.
<<NEUTIQUAM ERRO>>
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Sat May 15, 2021 5:08 pm

The placement is set yet. I still need to trim the outside brim.
Jaeger wrote:
Fri May 14, 2021 10:08 pm
red wrote:
Fri May 14, 2021 4:42 pm
Should they be bigger?

PXL_20210514_193236700.jpg
No, those look right to me.

--Jaeger
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Mon May 17, 2021 5:11 am

Fuel T leak resolved!

Now, cylinder 3 is acting up. Which is weird, because I'm 99% positive it was cylinder 2 last year. Both coils 2 and 3 are together. I've never really dealt with a coil issue before. I did reseat the plug wire into the coil, hopefully it's something that simple. Once that is resolved, I need to balance the carbs again.

I did install the plate brackets I printed (with some modification), as well as LED plate lights.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Thu May 20, 2021 9:22 am

I'm gonna blow this place up with replies and necro old threads because I miss it. Remember the good ol' days?

Anywho....
Have some more garage time scheduled this weekend. I'm at the testing point where it's all noisy stuff I can't do while the kids are asleep (stupid but handy attached garage). I'm really thinking about paying someone to rebuild the forks once I get past the carb stuff. I'm tried of wrenching, I want to ride dammit. Lots of my gear is really long in the tooth, so I need to start replacing it.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Fri May 21, 2021 3:00 pm

Printed my headlight ears, and now I started the bucket. It's gonna take a few tries to get it right. Hopefully the LED bulb doesn't melt it.

Oh yeah, the water pump o-rings arrived today, and I ordered my fork seals.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Mon May 31, 2021 6:40 pm

Over the last 2 weekends, I've taken the Hurricane out for a few test rides. The first series resulted in a weird issue with the idle needing constant adjustment at every stop, as well as the bike dying a few times, and an annoying stutter/surge feeling around 5.5K. I found a small vacuum leak on carb boot 1, which was easily resolved by reseating the carbs and using some Dielectric grease as lube. The idle issue turned out (I made a pun!) to be a missing tension spring from the adjuster. An Ootmik on FB suggested the adjuster could have been spinning itself out, and he was correct. I checked the idle adjuster on my spare carbs and noticed the spring. Oh yeah, when pulling the carbs to reseal them, I snapped the plastic fuel T. Which are made existent from Honda. Luckily, the moto gods smiled upon my toiling and called it good; as I was blessed with finding a custom made metal T from eBay.

With those two issues resolved, I rebalanced the carbs and noticed the overflow was, well, flowing from carbs 3/4. It stopped when I got them balanced. The only issue I had on my test ride was that hesitation between 5.5K and 6.5K (ish). I can power through it and keep rocking. Some sleuthing uncovered I may need to adjust my mixture screws out since I'm running a K&N air filter, as well as a full Delkevic exhaust.

My test start resulted in the same fuel flow from 3/4. This time, it didn't stop. I pulled the carbs again (getting good at this), swapped in the floats from the spare carbs (they were rebuilt by a coworker about 10 years ago as a spare set for his race Hurricane). I decided that I might as well check out the o-rings on the pilot screws since I've replaced all the other o-rings on these carbs. Yup, they're rough. Unfortunately, I haven't been able to find the stock size or measurements. I was able to order other o-rings from a place in the USA, so I sent them a message to see if I can mail them a spare pilot screw assembly so they can size the o-ring for me. Never hurts to ask.

Once I have the pilot screws ready to go, which by the way no longer have the annoying EPA required limiter caps, we'll see how things turn out. If I continue to have issues, I may just take it in to be dyno tuned.

Oh, I still need to replace the fork seals and a few other odds and ends. It took a few attempts but I finally printed a headlight bucket. I'll be swapping that over when I do my fork seals. From there it's tires and ride ride ride. Then hopefully 5 days of moto fun in Oct for Do0M!

If you want to see pics, check the blog. I'm too lazy to upload them twice.

https://7plus8.blogspot.com/
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Wed Jun 16, 2021 4:58 am

The fork seal transplant seems to be a success. We'll see if the left seal leaks since there are some scratches in on the tube. I had heard the allen head bolts on the bottom were an absolute terror to remove. Thankfully, about a year ago, I bought a Ryobi battery powered impact gun. Worth every fuggin penny. However, I did have to track down some long reach allen sockets at Harbor Fright. All in all, the fork seal job was easy peasy. My 3d printed driver didn't cut it, so I had to get some 1.5" PVC and use the old backup washers as drivers. My net printed version will be much higher infill rate, that should remedy the issue.

Tonight, I'll put the exhaust back on which, btw, wasn't even tightened down properly at the exhaust ports. Guarantee I had leaks on at least cylinders 1 and 3; which is pretty evident with the amount of carbon in the pipes. I also need to reassemble the headlight cluster. All quiet work I can when the kiddos are in bed.

For father's day, I'll be leak testing the carbs (again) and doing a test ride if that goes well.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Thu Jun 17, 2021 10:27 am

Exhaust is back, man that was a pain in the ass. I had to pull the pipes off the collector and when I finally got them and the collector tight, I must have slightly changed the angle so the mid pipe was hitting the swingarm. The header/collector pipe on my XJ was one solid piece, an old Yoshimura pipe. Learned my lesson, never tighten those first! I ended up piecing together a spacer from some old Jeep bushings I had. Whatever works, right?

The front end wiring is all back in place. I swapped out the headlight DRL white to orange, to break it up a bit. Looks better. Sunday will be the real test, well, maybe tomorrow if I WFH. If she holds her fluids, I'll be riding to work on Monday for Ride To Work Day. Tires will be ordered soon, so that should be the last major bit.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Mon Jun 21, 2021 5:03 am

I recruited my step father, who, I believe I've mentioned before. He's from Japan, long time flat track racer, here and there, as well as a damn good mechanic. He's the lead mechanic at our local Trumpet shop. My availability for loud work, test rides, and etc, is slim right now. Can't do that stuff when the kids are in bed; which is when I get most of my free time. So, he offered to assist.

The plugs are indicating a definite lean condition, K&N filter, no fairings, and a full open Delkevic exhaust (no baffle). So, I've ordered a plethora of main jets, and a set of larger pilots. If I can't get this squared away, it's gonna be DooM 2022. =\
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Wed Jun 23, 2021 9:36 am

My own personal vintage copy of the good book (87 CBR600F Honda FSM) should be here today, and the jets should be here on Friday.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Wed Jun 23, 2021 10:24 am

Well fuck a duck. I pulled the carbs and started stripping them down over lunch, the mains are 105s for some reason! I guess that's what I get for not verifying the sizes. I could have sworn I checked all the jet sizes back in 2019 but I guess I didn't.

Oh well, 110s, 115s, and 118s are on order too. Rather have spares than have to wait even longer.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Thu Jun 24, 2021 8:41 am

haha! I was correct, there were 110s in there to begin with, which explains why it did run pretty well the very first time I took it out in 2019. Then.... I ordered bowl gaskets that included the jets, which I swapped out. The new were 105s. Now... where did I put those 110s?

Also, my book and larger mains (120+) arrived yesterday. Huzzah!
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by Bigshankhank » Thu Jun 24, 2021 2:21 pm

As white as those plugs were I would think you'll be at 115 at least. Good luck fiddling with the brass.
It's time for Humankind to ditch the imaginary friends of our species' childhood and grow the fuck up.
-Davros

"Lasse mich deine Seele dem Herrscher der Finsternis opfern"

Let me sacrifice your soul to the ruler of darkness

Always carry a bottle of whiskey when you travel in case of a snakebite. Futhermore, always carry a small snake.

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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Thu Jun 24, 2021 5:23 pm

I have the 120s in now. Will finish reassembly another night.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Sat Jun 26, 2021 4:32 pm

After a little bit more garage time today, I've decided that I'm just going to go ahead and farm out the last work to my stepfather. He's a hundred times the mechanic I would ever be, and has the time to do it. Me getting an hour here and there is causing me more frustration than progress.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Thu Jul 08, 2021 10:37 am

No major changes or updates to the bike. However, my back issues have popped back up with a vengeance. I know it's just the beginning of July but dammit Oct is gonna be here before long, so I'm running out of time. Bike isn't trip worthy, hell isn't really road worthy, and now I'm not either. TBH, I've had my doubts about the hurricane's ergos from the beginning and this recent flare up has me thinking hard about that. Is a hunched up 2000 mile trip going to wreck my spine?
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by Jaeger » Fri Jul 09, 2021 6:00 am

red wrote:
Thu Jul 08, 2021 10:37 am
No major changes or updates to the bike. However, my back issues have popped back up with a vengeance. I know it's just the beginning of July but dammit Oct is gonna be here before long, so I'm running out of time. Bike isn't trip worthy, hell isn't really road worthy, and now I'm not either. TBH, I've had my doubts about the hurricane's ergos from the beginning and this recent flare up has me thinking hard about that. Is a hunched up 2000 mile trip going to wreck my spine?
Considering I threw my back out last night too... well, there are reasons I switched over to cruisers, or at least a more neutral riding position. Admittedly, chopper slouch is real, but shortly before my back detonated last night I manged to install the new 2" risers on Lilah, which seems to have solved the ergos. I'll only know sometime... shit, next week after my back un-clenches.

--Jaeger
Bigshankhank wrote:The world is a fucking wreck, but there is still sunshine in some places. Go outside and look for it.
<<NEUTIQUAM ERRO>>
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Fri Jul 09, 2021 6:58 am

I've graduated from pain to numbness in my lower meat suit. Fucking terrible and scary. With the Hurricane, about the only thing I can do is get the hardware to add mx bars and see if that helps. Getting myself into better shape wouldn't be a bad idea either.

If I end up going to a different bike, I'm going smaller. My wife has no plan to ride with me again. I don't need a 600cc sport bike, and honestly, high speed isn't my thing. Holding back is less fun than wringing out a small bike on back roads and I want to explore dirty back roads and light trails. So, I'm looking at a few options, like the CRF300L Rally and the BMW G310GS. I like the KTM 390 Adventure but for some reason, the insurance is stupid expensive. The BMW and Honda are less than my Hurricane for the same coverage but the KTM is double. *shrug*
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by Bigshankhank » Sat Jul 10, 2021 8:10 am

Two ideas; see if you can lower the footpegs, and download a free yoga app on your phone. I have Pocket Yoga, its simple, you can start at 10-15 minutes and build up to longer "workouts" as you get stronger and more flexible, and it makes a big difference in reducing back and joint pain. I am a believer.
You know I'm a fan of the 390 platform but from what I've heard in regards to the ADV variant, you could get 90% of the same capability just putting ADV tires on the Duke, the only significant changes are a different subframe made to mount aluminum boxes and another inch or two of ground clearance. I've read nothing but bad things about the G310. I would also consider the Versys 300 and the CSC RX3 which apparently there are a lot of people on ADVRider that have made a cottage industry out of their fandom for that bike.
It's time for Humankind to ditch the imaginary friends of our species' childhood and grow the fuck up.
-Davros

"Lasse mich deine Seele dem Herrscher der Finsternis opfern"

Let me sacrifice your soul to the ruler of darkness

Always carry a bottle of whiskey when you travel in case of a snakebite. Futhermore, always carry a small snake.

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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Sat Jul 10, 2021 5:04 pm

Bigshankhank wrote:
Sat Jul 10, 2021 8:10 am
Two ideas; see if you can lower the footpegs, and download a free yoga app on your phone. I have Pocket Yoga, its simple, you can start at 10-15 minutes and build up to longer "workouts" as you get stronger and more flexible, and it makes a big difference in reducing back and joint pain. I am a believer.
You know I'm a fan of the 390 platform but from what I've heard in regards to the ADV variant, you could get 90% of the same capability just putting ADV tires on the Duke, the only significant changes are a different subframe made to mount aluminum boxes and another inch or two of ground clearance. I've read nothing but bad things about the G310. I would also consider the Versys 300 and the CSC RX3 which apparently there are a lot of people on ADVRider that have made a cottage industry out of their fandom for that bike.
I'll keep that in mind about the Duke but as much as I want a fancy new(ish) bike, I don't want another payment right now. Maybe next year. so in the meantime, I broke down and ordered the fancy moto-CNC 37mm street fighter kit from eBay:
https://www.ebay.com/itm/224367952701?h ... SwEK5foaaB. I'm gonna order a set of super bike bars next week when I order tires. This should give me about 3" of rise and 3" of pullback; which I think will help quite a bit. I think the stock cables will work with a little creative routing. For the brake line, I have a spare long line from my parts bin, so I should be good. That one part, with shipping is damn near what I paid for the whole bike. But I did not like the idea of just drilling holes through the top clamp and installing bar mounts. So, buy once, cry once, right?

9x Ibuprofen and the prescribed exercise is helping but I put in a request to go back to the PT doc for more work. Fucking sedentary jobs are terrible. I like Yoga quite a bit but I have to be careful with what I do right now until I get the jelly back in the donut.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by Bigshankhank » Sun Jul 11, 2021 1:29 pm

red wrote:
Sat Jul 10, 2021 5:04 pm
I have to be careful with what I do right now until I get the jelly back in the donut.
You have two kids already, it should be obvious that putting more jelly in the donut won't solve your back pain.
It's time for Humankind to ditch the imaginary friends of our species' childhood and grow the fuck up.
-Davros

"Lasse mich deine Seele dem Herrscher der Finsternis opfern"

Let me sacrifice your soul to the ruler of darkness

Always carry a bottle of whiskey when you travel in case of a snakebite. Futhermore, always carry a small snake.

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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Wed Jul 14, 2021 11:53 am

Progress Report:

My back continues to improve! Much rejoicing! Should be in good enough shape come DooM, however, my stops will be more frequent and I must continue my current therapies. I changed my priority and I'm definitely trying to get the ergos improved before the trip.

The Hurricane hasn't been delivered for fine tuning yet. However today I pulled the carbs and polished the float valve seats, and found the cause for my failing neutral light (tiny LED wires are broken). Tires and new bars will be ordered this week, and the CNC adapters should be here next week. I thought I had a spare long brake line but I don't, so that should be here next week. I'd love to swap over to braided lines but I'm running out of money, and testing/fixing time. Should be able to get it all back together tonight and ready to go.

I still plan on camping on the way to DooM, and on my way home, possibly next to the X-Keys but we'll see. I'm working on a tarp set up to cover the bike and myself. The good thing is, I sleep on the floor, in the same system that I'll be using for the trip (just a warmer sleeping bag), so that shouldn't be a big deal.

This will be my first solo trip and I'd be a total liar if I said I wasn't a bit apprehensive. Plus, I've been off two-wheels for almost 5 years, so I'm investing in some additional safety gear. I dropped the cash for the Helite Turtle 2 vest, it's pretty damn awesome. Trying to get a deal on a Spot tracker too. Captain Safety reporting for duty!
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Tue Jul 20, 2021 11:02 am

Tires arrived, however, like a moron, I ordered the wrong rear size. The correct size is not available, and I want matching tires, so I sent back my Kenda K671s and ordered a set of Bridgestone Battlax BT46s from another vendor. I got my mx bars and grips; the 37mm adapters should be here this week. Found the broken wire for the Neutral light, and that the same is occurring on the oil light. I'm replacing all the LEDs and going to encase the back sides in a block of either epoxy or hot glue. Time to start putting in a few long nights again to get it all ready for Duh-ewwM.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Thu Jul 22, 2021 11:03 am

Fancy new shoes arrived today as well as my box o-copper-o-rings. Now, all I need is my handle bar adapter thingies and I can get cracking on the bar swap.
PXL_20210722_181434895.jpg
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Fri Jul 23, 2021 10:28 am

Got the gauge cluster lights replaced (broken wires on the LEDs), and the rest of the front end put back. Next steps are to check the plugs, adjust mains accordingly, then do the MX bar swap. The kit should be here Monday at the earliest, it hit our shores early this morning.

In the meantime, I did a test pack with my DooM loadout and it looks good. Managed to find my other waterproof camo bag, so I have matching saddlebags now. These hold a good amount for their size. Left side will be my camp stove and pot set, food, water, and fold flat wood stove. Right side has my 4x6 ground tarp, full tool kit, flat kit, chain lube, 10x10 tarp, and a fuel bottle. The dry bag will carry all my clothes, sleeping pad/bag, and US Milsurp bivy, plus other misc soft stuff. Tank bag, which is an Ootmik family heirloom (from Toonces > BSH > me), holds the rest of my stuff. I need to either make 2x PVC poles, or order some collapsible trekking poles to complete my tarp shelter.

I also managed to find an old Contour Roam a friend perma-loaned me. It still works, so I should be able to get some time-lapse pics and video.
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Re: Project Bike Thread: 81 GS650GL & 87 CBR600F

Post by red » Wed Jul 28, 2021 6:41 am

The plugs were a bit dark, so I rolled back to 115 mains. However, cylinder/carb 3 is definitely the one that was having issues causing overflow! The plug was gross and the piston crown wasn't much better. The Moto-CNC bar adapters are installed, took some grinding to fit around the stem nut but they are damn nice! Cable routing is tricky using stock cables. Had to use a rear brake line on the front to get the extra length. Should be able to install the carbs tonight and double check all routing. Then it's test time!

Oh yeah, I also used a drill, q-tip, and some brasso to polish the float valve seats incase that was the cause for the overflow (sticking). Since the all the piston heads were a bit carbony, and 3 was gross, I plan on doing a Seafoam Hot Soak like I did with my XJ.

I'm hopeful for DooM but also a bit apprehensive. as mentioned before but more so due to running out of time to thoroughly test the bike, as well as the looming threat of another wave of the plague. My backup plan is to just spend the DooM weekend moto camping in southern IN, but real DooM is preferred to diet caffeine free DooM.
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