Topic: Project "Hard Luck - The Red Racer" - updated 07/30/2010 w/new project!!!

[KB02]

Well, I was able to get most of the electrics wired back up. With the bars being replaced with clip-ons, I have a bit more wires in the head light bucket. It is one tight fit to get the headlight in there now, but:

Let there be light!
The horn is shot, so I will have to replace that. It just sounds so awful. 

The bike is starting to come together, though. I still need to space out the exhaust, though. The chain is hitting the pipe.



Here is my make shift Choke holder:


The starter sounds good. Now I just need to get some good cables (that I trust - vs. the old crappy ones - and I don't have a clutch cable at all right now) and some fuel line and I should be able to start it up.

... should be a couple weeks before my cables get here...

[KB02]

Choosing a starting point for new jets:
http://forums.sohc4.net/index.php?topic=56971.0

[KB02]

Having issues getting the neutral switch in place:
http://forums.sohc4.net/index.php?topic=57004.0

[KB02]

Having issues getting the neutral switch in place:
http://forums.sohc4.net/index.php?topic=57004.0

Got the switch in place. Got my new clutch lever. Just waiting on cables. I might have to try to start it up before I get my new cables. I know they say that's a bad thing to do from an engine beak in standpoint, but I'm kind of sick of waiting, you know?

I took some measurements last night and it looks like I got the size of my rear spacers wrong for the Katana rear wheel. I'm about 9/32" off to the left to keep the rear wheel perfectly in line with the frame. The brae side spacer will be easy to just mill down, but the chain side will have to be re-made to make it longer. From what I can tell the chain is lined up well, so I will need some spacers for the sprocket. 1/8" washers ought to do, eh?

[KB02]

Once I had the oil in, I gave it a few good kicks to try and help circulate the oil a bit. It takes just about all 200 pounds of myself to kick this thing over. Once I get the wiring done (I know! I know! Get on it!!!) I'll do some compression tests with the electric start to see just how much compression is in these cylinders.

My compression tester is not working for some reason. It won't hold pressure so I can read it. I pulled the schrader valve and put some oil on it in the hopes that it was just dried out. I've been letting it sit for a bit. I'll check it again tonight and go from there.

Fuel lines are all plumbed. I put in an in-line filter and I'm not sure if it's going to work or not. Something about it just doesn't seem right. We'll find out, though. I plan to run a little fuel tonight if I have the time (Video camera at the ready...  )

I do have one electrical issue that I haven't been able to figure out just yet. Where the wires come out of the loom for the Horn, there are three wires - one light green, one black and one dark green. I know the first two go to the horn (Boy does that horn sound like sh!t. I will have to get a new one of those, too), and I know the dark green wire is a ground, but for the life of me, I cannot find what it plugs into. The wiring diagram isn't much help in figuring it out. it's the female end of a spade connector.

[Spikeybike]

lookin good KB ... just the little stuff to work out ... can't wait to hear those pipes

[KB02]

Got no gas flowing into the carbs. Looks like the inlet is blocked up (and here I thought I had them all cleaned out...). Well, as the usual with the SOHC, once you think your carbs are cleaned, clean them once or twice more and you should be all set. 

[KB02]

After a little fiddling with the carbs a bit, and after two and a half years of work, I am finally able to post this video:



My wife was at church when I took this video. When she came home I started it up for her and she said, "My bike." 

Still a lot of work to go on this:
- I have got to get the seat made.
- I have to get the rear wheel realigned.
- I still need to get my new cables from Motion Pro.
- Forks need to be rebuilt.
- Gauges need to be mounted.
- New rear shocks are needed
- Paint
- Lots of other little stuff, too, I'm sure, that I will find along the way.

...BUT...

IT'S ALIVE!!!!!!!

... and those pipes do sound awesome. 

[andy750]

Well done!!! Those pipes do sound amazing!!

cheers
Andy

[bikebitzofvt]

KB~
That sounds AWESOME!!!  Great work!  
I have cable ends from Flander's if you'd like to try to cut yours down & solder them - drop me a pm & I'll send ya some.

You'll be terrorizing B-town with it come spring

T

[delay pedal]

that sounds amazing

[HavocTurbo]

Holy #$%* that sounds great!!!

If you're looking for progressives give me a call.

Amazing work man. Hope to see it on the road soon!!

[KB02]

After letting it sit in my mind overnight, I realized that I'm acting like a dork in the video, but I was just very happy to get it running.

As for the cables, they are already on order and should be here sometime within the next week or so.

As for shocks, I was planning on going something a little higher end with a bit more adjustability. Since I grafting on suspension parts that are a decade+ newer,  figure, I'll want to be able to fine tune the ride as much as possible to compensate.

Things I've learned from the first start:
- The idle needs to come up. The adjuster screw is sitting in behind the fuel valve - the perils of using the K2 tank on the K8
- I did not need the choke to start the bike. With choke it simply sputtered. Not quite sure what to make of this one, but we'll see how things sort out once carbs are synced.
- There is something wring with my starter. After the first couple of start ups, the start would start to catch and turn the engine and then just spin free. That's something else I'll have to dive into at some point - but that's also why it's a good thing I have the kick starter.

[MCRider]

Glad its ALIVE!

As to your starter, there is a triplet of "springs, caps and rollers" in the starter clutch behind the alternator. When they start to slip like that, there is no shortcut, the springs must be replaced. They are about the size of ball point pen springs. Since you're in there, most will replace the caps and rollers too.  About $12 to $20 worth of parts.

 If you've never seen the affair, it will be a learning experience. The clutch itself is rarely the problem, I've never seen a starter clutch fail. The springs become fatigued with heat and age. And the more it slips the more you wear the engagement rollers.

[Spikeybike]

OMG i want those pipes ...  WELL DONE KB   .... well done indeed

[DollarBill]

DUDE!  I AM SO STOKED FOR YOU!!!  Great job and the pipes are unbelievable!  Keep it up!

[Laminar]

I love what you'd done with your engine mechanically, and it's exactly what I had in mind for my bike. If you don't mind, how much did the 850 kit, head porting, and cam cost you?

[KB02]

I love what you'd done with your engine mechanically, and it's exactly what I had in mind for my bike. If you don't mind, how much did the 850 kit, head porting, and cam cost you?

850 Kit:
   Kit itself: $250
   Boring and honing: $350
Head porting:  $500
Cam:  $200
Total: $1300

There are also a lot of little things like new springs, total-seal second rings, clutch kit, stuff like that.

[Laminar]

Thanks for the info. I'll definitely be saving my lunch money for this.

[HedNut]

WOW.... I'm in awe.  Your bike sounds something like a phenomenon.  I'm very impressed...and I think I'm with many other people on here....this whole project is SCRUMTRALECENT.  Good work!

[KB02]

Got my new cables from Motion Pro. Throttle cables are spot on, but the clutch cable could have been an inch or two shorter. Oh well. It works just fine. After getting the cables all in place, and having the use the throttle a couple of times, I notice that carb #3 doesn't spray very well as compared to the other three from the pumper. I'll have to look into that at some point.

[Laminar]

Got my new cables from Motion Pro. Throttle cables are spot on, but the clutch cable could have been an inch or two shorter. Oh well. It works just fine. After getting the cables all in place, and having the use the throttle a couple of times, I notice that carb #3 doesn't spray very well as compared to the other three from the pumper. I'll have to look into that at some point.

Search eBay a bit for CB750 or CB550 cables, there are quite a few different lengths listed under those bikes. I managed to find the perfect length for my Clubmans by going though a bunch of different auctions. Now that you know the length of a cable that's a couple inches too long you know what you're looking for.

[KB02]

Thought I had problem with the rear wheel being off center, but it turns out that I am all set after all.
http://forums.sohc4.net/index.php?topic=57826.0

[KB02]

With the engine running, I figure it won't be too long before I'm actually able to ride this thing. I guess it's about time I started working on the brakes, huh?  The front brakes are fine. They need to be drained and have fresh fluid and pads, but other than that, they are fine. It's the rear brake that I have been dragging my feet getting set. About the only part of the stock set up that I am using for the rear brakes is the locator arm. Everythign else is being done from scratch (even the mounting point for the locator arm).

I got the Katana's rear MC positioned where I wanted it and then took some measurements.


As per most things that I do, I made up a little template out of wood to make sure I had things mounted where I wanted them.


Roughly the same mounting position as on the Kat. I had to add some spacers on the back side to make sure everytihng will line up:


Then trace it out on some aluminum I had lying around:



After cutting, drilling, tapping and a little bit more shaping, a test fit:


With the MC in place:


I need to get a couple of bolts to hold it in place, but it should be all set to go. I should have plenty of room for the hose and the brake light switch behind it. I'm at work right now so I'll have to play with it a bit more when I get home.

[KB02]

Wasn't an much room as I thought for the hose. Looks like I will have to do a bit more looking into it. I might be able to get away a different bend of the banjo. I have Wednesday off from work, so that will be my time to play. I'd also like to start fiberglassing the seat that I have started on Wednesday. We'll see how that goes. After that, it is time to get ready for Vacation. I'm heading over to London.    I'll have to keep my eye open for some SOHC4er's over there.