92 VFR Project.

Long story short, I picked this bike up in November 2009, haven't done much to it outside regular maintenance. Went to Korea from December 2011 until December 2013, it was in storage. She had 25k on the clock when i bought her for $1500 and has had another 25k put on her since. Including a cost-to-coast-coast trip in spring of 2011. I have redone the fork seals, replaced the complete exhaust, rewired the stator connection because it was fried, as well as the starter solenoid and the plug for R/R and recently replaced one of the choke arms. NOW that I have the time to get into the guts of things, I am noticing more and more w gone bad/worn out in this old girl. Plastics cracked, pieces missing, starter clutch is broken (finally started sounding like a dentist's drill), some bolt hole threads stripped out. Anyway, here are some pictures of this old poorly maintained machine. BTW, the guy I bought it from apparently had that paint job done with paint markers.

 

Think of her as a labor of love!! Keep on keepin on fixin the old girl up :thumbsup:

 

Thanks, i'm going to start with the plastic welding soon... wondering if i should have someone re-do that paint scheme though.

 

What are these nuts called?

 

I always called them "castle" nuts because of what the needed socket looks like.

The FSM usually lists the part number of the tool needed.

 

See also "castellated" nuts. There are drilled bolts that make up sets. They are used much of the time with safety wire or clips. Some even come as Nylok types.

 

I made my own tool by taking an old socket and grinding it down until I had two tabs to remove these. I tried to make the four tabs but it was much easier to create just the two.

 

Any chance i could get pictures of that?

 

Once you get the outside spanner loose the inner Allen comes out easy. One of mine was really tight so I had to tap it with a hammer and small punch to loosen it before I used the homemade spanner tool. There are two different sizes so you will have to make two tools.

 

Awesome, Thanks.

 

Next part needed.... STARTER CLUTCH!!! I swear, if isn't one thing, it's another. This one appears to be broken in the three typical places. Maybe I'll get lucky and NOT break the bank getting it replaced.

 

BTW, new fiberglass fairing available from Airtech, if desired.

Larry

 

Wasn't sure if theirs were fiberglass or composite.