Doward's build thread - part 2!

enriquez said:

Hey Doward, did you get my last PM? Still a possibility?

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Yes, I did! I just haven't had a chance to get back out to storage and snag those pics for you... I'll do my best to hit that tomorrow for you!



As for the paint, yep - it's high temp 550F Engine Paint

Doward said:

Yes, I did! I just haven't had a chance to get back out to storage and snag those pics for you... I'll do my best to hit that tomorrow for you!



As for the paint, yep - it's high temp 550F Engine Paint

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Got the exhaust on last night, and started something I really didn't want to do (yet) - pulled the wiriing harness completely apart, and getting started on completely rewiring it, so I can hide and tuck that wiring away.



I'll post pics tonight of the blacked out exhaust with chrome rings

DAMMIT!!



Got the new right caliper in and on, vacuum bleed the brakes - very little feel at the lever.



WTF, right?



Pull the master cylinder apart - Minimum piston diameter = 0.5488", my piston diameter = 0.5205"



DAMMIT DAMMIT DAMMIT!



Ok, so raiding the parts bin now to see if I can find another master cylinder piston. I think I have an '82 style master cylinder around here somewhere, I just prefer my '78 round all-metal system



*edit*



Nothing. Looks like I'm buying a new one. No riding for me this weekend.

Managed to get my hands on a brand new rebuild kit for the master cylinder, got that all done, and I STILL don't have good pressure! I can squeeze the lever all the way down, and still don't have good pressure. This is AFTER vacuum-bleeding the brakes. Ugh!!!



I noticed that if I squeeze the lever with the MC cap off, the left hole (while sitting on the bike) SHOOTS brake fluid up and out - is it supposed to do that? Seems like that's where my pressure is going? I've got all stainless steel lines now, so there shouldn't be any flex going on....



So next up is torquing the front axle down (remember, I've got an '82 VF750C front end on the CX now) - and the damn left fork is stripped where the axle bolts down. Tomorrow I have to try to track down an m12 x 1.25 helicoil set, otherwise I've got to order one off the 'bay, $44 shipped. Wonderful.



Anyway, pics from today:



How it started:





How it ended:

So doing some diagnostic-ing revealed I had what seemed to be a lot of fork 'flex' when I was pulling the brakes.



Odd, as the 'flex' appeared to be heavy at the bottom of the fork.



Imagine my surprise when I go to torque down the front axle and find out that the receiver threads ARE STRIPPED OUT.



Ugh - CarQuest saves the day ordering me an m12x1.25 helicoil kit - and all is now well. Accomplished another couple of rounds of my new favorite activity (CAUTION: THIS MAY BE SARCASM) of Prime the tank / Sand the tank / repeat



At least the tank bodywork is ALMOST complete - I'm being pretty anal, as I want the tank to be pretty when I paint the bike in my Dark Blue Pearl:



(example)





I'm hoping to FINALLY take her on a shakedown run tomorrow!

GreenCXman said:

Doward, the bike is looking great and sounding good too.



I had those low points as well last winter in the middle of my custom re-build. Thankfully I had some good friends that came round and verbally abused me to get me going again.

Have the longer forks of the VF made any difference to the front end ?



Mike.

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Well, the front end is definitely higher!! Also, the tubes contact the tank if I'm going for a low speed u-turn scenario, but I don't think they will still contact after I rake it out



I do think 20wt oil was too much, as the front is REAL stiff, with minimal dive, and I haven't even put air in the forks yet!



Rather angry, as the old red primer I had laying around actually PEELED UP when I shot the paint - so I'm re-doing all the work on the tank. Not my idea of fun, but it's coming along (again) nicely.



Also, put a 5/8" master cylinder from an SV650 on the brakes - WOW what a difference!



So if anyone needs a fully rebuilt '78 round style master cylinder, let me know

Managed to work on the bike more today - another 3 rounds of prime / sand / dry / repeat.



More interestingly, though, I finally started on the carb overhaul. Completely disassembled, all rubbers removed, and dunked in a 60/40 Pinesol/Water mix, heated, in the ultrasonic cleaner.



After 6 minutes in the cleaner:

LRCXed said:

Doward, if you want the sonic cleaner to do it's job, and last, you better fill it up more. It not only will burn out the unit, but the carbs won't clean properly inside.



A tip that I learned a long time ago is to put a better bead of silicone sealer in the seam where the tank meets the top plastic cover. They tend to leak inside if you don't. The factory misses some spots when the mass produce them. BTW, I have not seen as good of results using the pinesol as I do with the simple green. I'll post pictures some time of what I did testing it.

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It's up to the MAX line, so I'm assuming that's where it's supposed to be...



Pic of one carb done