Forward Planning And Removing Sylvie’s Carburetor

Last week, I decided to continue my forward planning and finally rewrite the lists for the Honda projects.

I started by erasing the lists altogether.

I then consulted the transcribed lists ans set about recreating them

I added a battery to the list for Erica, as the one I’m using in her is not holding its charge well and I suspect it’s faulty.

I then made a list of parts that the bikes would benefit from that will be needed for tasks in the main lists and hung it on the back of one of the shed doors, so that I see it when I’m leaving the shed.

I found a list of shed tasks I had started some time ago that needed updating.

Since I haven’t managed any of the stuff on the list yet, I added to it and put it inside the the other shed door so I’ll see it when I’m leaving the shed too.

The new lists worked, as I ordered a carb kit for Sylvie. Since it’ll be arriving this week, I decided to remove the carburetor ahead of time and have it ready to rebuild.

Off came the seat and side panels.

I decided to put all the bolts into a magnetic parts tray that had all other bolts and parts removed first.

After removing the tank, I put the tank and side panels aside so they wouldn’t get dropped.

Next up was the battery.

With the battery out, I stacked it on top of my growing collection of dead or dying batteries – It might be time to drop them off for recycling soon!

I disconnected all the electrical connections ready to take out the battery frame and attached electrics.

I can never seem to remember which of the 3 wires go on the flasher can, so I  took a photo before disconnecting it this time.

I took out the battery frame with the electrical components still bolted on and put it with the other parts

I found the overflow hose for the battery had come off when I removed the battery, so I put it back on the overflow vent of the battery.

 

Next I removed the air intake and manoeuvred the airbox out of the frame. it went with the other parts.

I disconnected the choke and loosened the retaining nuts for the  throttle cables.

I moved the cables out of their mounting points

the disconnected the throttle cables and removed the carb.

 

Finally, I updated the parts list.

Next entry will most likely be either the carb rebuild or more teardown of the spare motor

 

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Filtered Air, Luggage Hooks And A Frame Bolt

I finally managed to track down the plastic frames to hold the air filter in, along with the filter itself and the sealing screws I didn’t know were missing in the form of a rather battered airbox from the local bike wrecker.

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 I also managed to get hold of a set of mounting screws for the luggage hooks I bought for her a while ago.

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I finally got the chance to install them on the Saturday before the gazebo disaster struck.

Firstly, the seat and rear grab handle needed to come off.

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Next were the rear “duck tail” fairings

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I tried installing the luggage hooks first to test out the screws.

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After realising that the rear fairings weren’t going to go back on over the luggage hooks, I took them off. I already suspected that the air filter frames weren’t getting in the airbox without disassembly, so I started to dismantle the rear sub-frame in order to remove the airbox.

Standard first step is to disconnect the battery.

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Next I unbolted the coolant overflow bottle, noting that it was pretty much empty.

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After removing the battery, the rear sub-frame needed to be unbolted to get the airbox out.

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At this point I noticed something fairly important was already missing!
There should be a hex-drive or “Allen” bolt where that hole is. It seems the previous one had fallen out after I put the airbox in last time.

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 I dismantled the rear sub-frame in much the same way as previously shown, pulled out the airbox, put the frames and air filter from the battered one in and put everything back together. Unfortunately I was in too much of a hurry to take photos of the process, as I was losing the light by this stage!

After screwing the luggage hooks in I realised I hadn’t taken many pictures and got a couple of the final result.

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Then I got a picture of Nix from her “good” side.

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After a short week week last week due to shoulder pain putting me out of action for two days, I was keen to get the missing bolt replaced.

On my way home from work on Tuesday, I discovered the left side indicators weren’t working at all! As it was cold, wet and dark, I rode her home extremely carefully and checked the wiring yesterday morning before leaving for work. While I was looking at indicators, I replaced the left front one as I’d been given an advisory to replace it when she had her rego inspection. As I was getting ready for work, I once again forgot to take photos!

A hectic work  schedule prevented me from managing to pick up a replacement frame bolt until today, so I installed it tonight.

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Finally, I got a shot of Nix from her “less good” side.

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The last few things Nix needs will be adjusting the rear monoshock, replacing the missing “glove compartment” cover along with any missing bolts and finally giving her a good clean and polish!

Miscellaneous Parts For Jack and Nix’ Inner Fairing Cowl

Yesterday I picked up Nix’ inner fairing cowl from the post office.
After I got home, some parts for Jack arrived that I’d been waiting on for a while.

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Jack’s left front indicator housing had been scratched pretty badly when the previous owner dropped him.

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Taking off the previous indicator housing required removing the headlight to unplug the cables

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The old housing in front of the new one for comparison

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Swapped the other parts into the new one and reassembled:

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Back in place. A few minor scratches on the lens but nowhere near as noticeable!

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Headlight back on and I realised I either need to polish the other one or wait for the new one to fade!

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On to the missing air box cover…

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Only one duct was available and some reason I also only ordered one screw, so I’ll be ordering another one of each

2014-05-31 10.46.00No idea why this one is sepia toned, My phone does weird things sometimes!

Slotted into place and screwed in. One duct and one screw are better than none!

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Now onto the front sprocket screws. The sprocket cover needed to come off.

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The bolts arrived arrived a while ago but I hadn’t put them on yet, as I’d replaced them with some generic M6 bolts.

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After taking the sprocket cover off, I found a couple of interesting things. A bunch of busted X-rings – either from the cheap chain I bought or the one it replaced  – and a fairing bolt I’d dropped when replacing Jack’s tank.

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The bolt was stuck in grease, so I was extremely lucky it was still there after commuting to and from work for a few days since the tank was swapped! Found where it came from while the seat was off.

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Put it back on so I don’t lose it again!

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The X-rings are a worry, so I’ll have to check the chain another day and see if there are any missing.

On to the bolts!

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After snapping the end off one of the original bolts, I ordered a replacement set. While I was waiting for them to arrive, I’d made do with high tensile M6 bolts with nuts on them as spacers. Temporary bolts above, genuine bolts below for comparison.

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As the genuine bolts shouldn’t need to come off for a while, I applied some threadlock compound.

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Adjusted the torque wrench to the specified torque (or thereabouts)

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Buttoned it back up and put the seat back on.

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After putting Jack’s seat back on, I moved him back onto the carport.

Back to Nix’ inner fairing cowl!

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I got Nix off the trailer and had a look at the task at hand.
I thought I’d taken photos of the side view but apparently I didn’t.

Lower front fairings off and it’s on with the cowl.

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After getting the front fairings back on again, I connected as much as I could of the inner cowl.

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The right side fairing still hangs a bit low with an obvious gap, so I’ll have to either look into repairing the broken tabs on that panel or replace it. Considering how damaged it is otherwise, I’m seriously thinking about either a repaired panel that will need painting or a “new old stock” one I found in the right colour.

Loaded Nix back onto the trailer and packed up the cardboard as I was done for the day.