Started in this weekend with the goal of getting the electrical sorted out. I didn't have any electrical problems with the bike when it was operational but I did plan quite a few upgrades. First on deck was the Hondaman ignition for better performance and spark. The second was a single unit Oregon Motorcycles regulator/rectifier. I was going to build my one based on instructions that I found here, but when I found a reduced priced prototype on ebay, I grabbed it and added it to my stash of parts. I also decided that I was going to run all LEDs in the bike wherever possible. The taillight, turn signals and neutral and oil light will all be LED. I am also upgrading all of the hand controls to CBR600F4 controls. They are pretty cool and have a great headlight cut switch when you hit the starter - which I think will be necessary for the small battery to crank the starter as I have removed the kick start.
On to the pics!
I decided to do a little bit of restoration on my gas cap. I had it rechromed but the inside was complete mess and there was on way I was going to be able to get a new gasket onto it in the condition that it was in. I gently pried at the four mounting areas to remove the gasket area from the cap itself. A small punch and a little patience and it comes right out. As you can see, mine were really rusted.
A word of warning on the following - Don't do this in your house if possible and whatever you do, don't use a good set of pots and pans for the following. If you live with an S/O send them shopping, open all the doors in the house and avoid breathing this crap. I used oxalic acid to remove the rust from these parts. The acid is essential wood bleach, which you can get at any good hardware store. The cool thing about the acid is that it won't eat chrome or paint.
I mixed up some of the acid - two table spoons and then added some hot water. I stirred until dissolved and the added the parts. I set the stove on very low heat as the purpose it to help with the chemical reaction between the acid and the rust.
After about 30 minutes of cooling on the stove, I pulled the parts out and washed them off really well and dried them with a towel as best as I could. I then placed them in the warm over (150 degrees) to dry out any remaining water that I couldn't reach.
They are not perfect but at least I know that my gas cap will not be adding little bits of rust in the gas and clogging up my carbs.
I ordered and received a stainless steel brake line from Z1 (great company, superfast shipping and amazing customer service). I mounted up all the hardware including the CBR master cylinder which I think looks a lot better on the clipons than the original factory equipment. I had previously had my caliper powder coated a gloss black to go with the wheels. It will be an interesting color combination, the black, red and silver.
The master cylinder contains it's on micro switch so I was able to run just a single line to the caliper, which cleans up the front of the bike a lot. Sorry for the blurry pic, my macro function seemed to be a little off.
I needed a good way to clean up the caliper arm which was covered in Honda clear coat. I applied some Easy Off oven cleaner (love the lemon smell!) and then took it to my wire wheel on my grinder using a brass brush. It cleaned up to the point where it is sparkling and fits right in with the polished lowers on my forks.
A view from the top. I custom wired in some 10mm LEDs for neutral and oil pressure - who needs high beams and turn signals? This is a cafe racer! I used a glue gun to further mount in the lights to make sure that they won't come loose and to make sure that they are waterproof. I am not sure on how happy I am with the mount for the tach as it sticks up a little farther than I would like. I am working on another way to lower it. It internal lights for the tach are still run on regular bulbs but I would love to replace with the LED lights. Anybody have a plug in solution for those weird sized blubs?
The headlight unit is an Emgo - I know - the cheap stuff, but the light looks good and is a H4 bulb so at least I will be able to be seen at night.
I finalized the rest linkage with a hogpodge of custom parts. It wasn't the easiest making these things work, although I am glad that I decided to do it. It makes the bike a million times more comfortable with the clipons. I am still waiting for the rear brake return spring, hence the limp pedal.
The shift side was a little more complicated but got everything worked out as best as I could.
It worked out pretty well. The shift feeling is firm and the transmission has a very positive feel.
Waiting on my wheels now so that I get can the exhaust on and get going with the bigger part of the wiring. I still need to put the carbs back on the rack and get them sunk again. And sort the wiring. And get the seat back from the upholstery. And finish all million of the little details that really make the bike.
Thoughts and comments are welcome. I love this forum and it has been a great source of information for my build.
I leave you with this
