Topic: The parts bike

[gregk]

I have started to rebuild my 75 parts bike after removing alot of pieces for the restoration of a 77 400F.  The 75 has sat in the shop corner for about 2 years and my curiousity finall got the best of me.  I was able to hot wire the bike and cleaned out the carbs and did a quick tuneup and it ran fine.  So now I had to buy all those part that I had previously removed.  It's been a slow process with purchases off e-bay but I am now getting to the point that It's starting to look like a bike.  As I have a complete stock 77, i thought i would build a cafe style "boy racer" without cutting or bashing anything. 
So far i have :
- rebuilt the front forks with new seals and boots
- built a cafe seat ( that took almost all last winter)
- completed a full tune-up ( built a carb balancer in the process) 
- replaced the bars and controls
- polished a bunch of alumimum parts
- got the seat covered
- replaced the headlight with a 750 unit
- replaced some spokes in the rear wheel
- fit a taillight in the rear section of the seat alon with a plate holder
- removed the front and rear fenders for the "look"
Now its a matter of collecting those little bits and trying to make the exhaust system look new.

It's been fun so far and it wasn't my intention to fix this bike as I had thought I would just keep the motor and sell the rest.  Funny how that happens!

Greg

[gregk]

I am fortunate enough to have a hydraulics shop next door to work ( Indequip) and was able to make a carb balancer by using some clear tubing and vaccuum guages with the carb fittings from Z-1.  It's the best investment I ever made as once you have been through a tune-up and balanced the carbs it makes a world of difference.  I've got a 750 F and its never ran better after the balance and I've owned the bike for 20 years! 
The seat construction took me all winter as it was an on and off sort of project.  i started with a foam core then covered it with glass and body filler.  The upholster was able to see my vision and did a good job, i think. 
Now on to replacing some of the spokes in the rear wheel and a new tire is in order.


Greg

[Hush]

Better to rebuild than part out if you can help it I say.

[gregk]

I wanted to give the bike a retro look and wanted to use fork boots.  After cleaning out the forks and replacing the seals, I measured the lip that the dust seal fit into and it's the same diameter as the 550 and 750's.  I bought a set of fork boots and used a piece of PVC pipe in the upper portion of the boot because the 400 forks are only 33mm in dia.  There was then the problem of how to finish up the top section of the boot.  I tried using the dust seal and it fits nicely over the fork boot top.  In the process of fixing up the front end, I rebuilt the brake piston after having to use a grease gun to get the piston unstuck.  Works great and here again the forum was there with the information.  Thanks once again.  I used stainless brake lines and also put a kit into the master cylinder.  The forks and the brake pieces polished up nicely and its back together again. 

[gregk]

I noticed that there was two loose spokes in the rear wheel and was able to order some from the local Honda dealer.  I researched the site and found that there was a very detailed article on spoking a wheel as well as trueing.  The two loose spokes were ruined, they would not tighten up so I started into removing the spokes.  Outers first and then inners.  This gave me a chance to clean the hub and polish up the brake etc.  This is alot easier than it looks but I will leave the final truing up to the bike shop.  My policy " never rule out professional help".  Also time for a new rear tire at the same time.  One question I have is regarding the bolts that hold the rear spoocket to the hub.  Three came out with no problems,the fourth started turning.  i ended up tr-tightening that bolt and then loosening it.  There doesn't appear to be anything in the hub that prevents these studs from turning or is that the way it is?  All the studs came out with the sprocket.  The old sprocket was made out of plastic which was new to me.  Apparently not a great idea according to some on this site.  Now its just a waiting game for the spokes to arrive.

Greg

[gregk]

Finally got back to the shop and was able to get the rims back together and some new tires at the same time.  Replaced the bars with some stock item and replaced the chain and sprockets.  Just have to bleed the front brake and wait for the snow to melt. 

[Alan F.]

Inspiring.  Thanks for the pics, very, very nice.