Another '99 5th gen restoration

Discussion in '5th Generation 1998-2001' started by w3bdevil, Oct 2, 2019.

  1. adk_finn

    adk_finn New Member

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    Nice work! I would suggest a few things since you have gone this far:

    - brakes - replace the caliper piston seals (it is harder to visually assess if they have gone bad or started to swell/sag) Were the front brakes dragging at all when you rolled the bike around? I didn't replace my piston seals and it is one of the few things I regret not doing while I had the bike torn down.
    - replace the all the bearings in the suspension linkage & mounts. These aren't too expensive and it makes a lot of sense to do while you are in this far. replace all the cush drive rubbers and also the bearings in the hub. 20yrs is a good service life and you don't want to have to do this again in a year or two do you?
     
  2. w3bdevil

    w3bdevil New Member

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    Piston seals will be replaced and also the rubber boots for the slide pins. The rebuild kits I got also have new pad retaining pins although the old ones would probably still go after cleaning. Front brakes were not dragging but some of the middle pistons were already slightly stuck.

    About the bearings. The bike only has ~40km / ~25k miles on the clock and there was no play at all in the rear axle. Bearings run smooth, they are clean and still have grease on them so I'm not sure if they need replacing. I guess bearings don't go bad with time alone. Cush drive rubbers were already broken and very hardened so they will definitely be replaced.
     
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  3. w3bdevil

    w3bdevil New Member

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    Oh the amount of scrubbing... Finally the brake parts are almost all cleaned and first (rear) caliper is ready to be put back together.

    [​IMG]
     
  4. w3bdevil

    w3bdevil New Member

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    A quick question about the exhaust pipe. Mine's rusty and I'd want to get it sandblasted and coated with something that will last longer than just a basic rattle-can heat resistant paint. I've got an offer for sandblasting and ceramic coating with Tech Line Black Satin (which is cured in oven like powder coats) for 200 euros (~220USD) but then again I could get new Lextek/Delkevic/Black Widow stainless pipe for 300ish (~330USD) and I can't decide which way to go. I guess the original pipes will fit better but I don't have any experience with these cheapish aftermarket manufacturers and their quality is a big question mark for me. So, which way would you go?
     
  5. Diving Pete

    Diving Pete Insider

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    This isn't really the correct thread - but the standard parts are fine - just but not anything to write home about ?
    A set of stainless pipes from those 2 will last the length of your ownership - again NOT the best quality but will 'fit' & be fine.
    Spending roughly the same on fixing yours 'may' not be the best use of your money unless you are determined to keep it 'original'.
     
  6. w3bdevil

    w3bdevil New Member

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    Here's what the headers look like. Not too bad but once they're off I'd like them blasted and coated.

    [​IMG]

    After getting the bike in small pieces it's rewarding to actually get something together again. Rear brake caliper almost complete.

    [​IMG]
     
  7. w3bdevil

    w3bdevil New Member

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    It was finally time for the VFR and the PAIR system to part ways. The reed valves and covers had carbon-like dirt in them that you get from exhaust gases. Could the valves have been leaking the wrong way or is this normal?

    [​IMG]

    [​IMG]
     
  8. GreginDenver

    GreginDenver New Member

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    Nice work, when I did my refurbishment work on my '99 5th Gen in the Fall/Winter of 2016-2017 I didn't do the Pair block-off but now I'm liking the clean look that results from removal of this item. Where did you source the block-off bits from?

    Because it's been a while since I did any research on the Pair-delete pros and cons, what are the known advantages and disadvantages (if any) of doing this modification.
     
  9. w3bdevil

    w3bdevil New Member

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    These came from an ebay seller bertye1958 based in the UK. Others correct me if I'm wrong here :) Since the PAIR system introduces clean air into the exhaust, it might throw off the ECU air-fuel ratio adjustment based on the lambda sensor values if a Power Commander or similar is being used. 5th gen does not have the sensors of course but I guess it could still affect measurement if doing PC tuning in a dyno (which I might be doing in the future). It also saves a tiny bit of weight and reduces the clutter "under the hood", the importance of which kind of depends on your point of view. As for disadvantages, according to Honda the idea of introducing clean air into the exhaust is to help in burning any remaining unburned fuel thus reducing emissions, which obviously will not happen after the system is disabled.
     
  10. w3bdevil

    w3bdevil New Member

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    A small bit of progress again. Got the throttle body apart and sent the injectors to be checked/cleaned. Here they are cleaned with new seals. They all were ok under pressure and spray pattern good too. Max flow rates from 270 to 276 cc/min, so inside 2,2% tolerance. They also did a dynamic test of 8500 impulses with 3ms duration and results were between 91,0 - 92,0 cc so within 1,1% tolerance.

    [​IMG]
     
  11. w3bdevil

    w3bdevil New Member

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    Got all the brake calipers finished today, plus the secondary master cylinder. I also did open and clean the no-return ball valve in the secondary master cylinder although none of the manuals I've seen states it's a serviceable part at all. After hours of scrubbing the rear suspension parts are also now in pretty good shape. All the bearings felt good so I just cleaned and repacked them with grease. Some dust seals were worn so I replaced those. The previous owner(s) have lost a few original bits and pieces and replaced them with something they happened to have on hand so I replaced those with original parts too.

    [​IMG]

    [​IMG]
     
  12. GreginDenver

    GreginDenver New Member

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    I'm really enjoying your work.
     
  13. Darth Vader

    Darth Vader New Member

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    Also loving this thread. Yourself and GreginDenver will have the best 5th gens on the planet
     
  14. w3bdevil

    w3bdevil New Member

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    Thanks! For me this is one of those 'if it's worth doing it's worth doing right' things.

    Now it was time to do something for the very dirty throttle body. Here I'm cleaning the starter valve mechanism. Numbers on the paper are turns I counted when disassembling so I can put them back to where they were.

    [​IMG]

    Starter valves reassembled and the throttle body somewhat clean. As you can see I'm not going for 'showroom clean' on the outside of the parts.

    [​IMG]

    Injectors, vacuum pipes, fuel rail and wiring harness back in place. Pretty much ready to go back on the bike once it's ready. I reused all the vacuum pipes after cleaning them and using some rubber+vinyl care thing on them. I also realized that the pipes going to the airbox actually have cylinder numbers printed on them. Nice thinking Honda.

    [​IMG]
     
  15. Diving Pete

    Diving Pete Insider

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    just a quick point - I will put money that the starter valves are unbalanced - I think they are out from the factory... lol
     
  16. w3bdevil

    w3bdevil New Member

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    Could be and me taking the thing apart, cleaning and putting it back together has likely thrown it off anyway so synchronization has to be done for sure. Counting the current setting and putting it back roughly where it was is just trying to get to the ballpark so the syncing would be a bit easier/faster than going from zero.
     
  17. Duc-fan

    Duc-fan New Member

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    IMG_6120.JPG IMG_6121.JPG Nice work:) and very good inspiration. Doing the same this vinter on a 2000 5-gen. Keep up the good work and post lot of pic. ;)
     
    Last edited: Nov 9, 2019
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  18. w3bdevil

    w3bdevil New Member

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    Thanks! I'm a bit envious about the stand, mine is on the floor and I've already got a back ache from the poor working position. Has your project escalated a lot yet? My thinking tends to go along the lines "now that I'm this far, why not do that too..." :)
     
  19. w3bdevil

    w3bdevil New Member

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    Ok so today I got to checking the valve clearances and I got some tight numbers, even a bit too tight for my taste. Everything was either very close to the tight side of service limit or under which I find both a bit odd (on a 5th gen with 25k mi / 40k km on the clock) and slightly annoying. The project just got a few more hours added into the pile. Now I have to go taking more stuff apart, chasing shims and all that. Anyway I'm glad that I did check since adjustments clearly have to be made. Here are the raw figures (in mm):

    CYL #4 ------------ CYL #3 ------------
    EX 2 0,28 IN 2 0,10 IN 2 0,10 EX 2 0,26
    EX 1 0,28 IN 1 0,13 IN 1 0,13 EX 1 0,26


    CYL #2 ------------ CYL #1 ------------
    EX 2 0,26 IN 2 0,14 IN 2 0,14 EX 2 0,27
    EX 1 0,26 IN 1 0,14 IN 1 0,13 EX 1 0,26
     
  20. Duc-fan

    Duc-fan New Member

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    Well - to make a 20 year old bike fresh again + satisfying ones small OECD thence to make projects grow :)
     
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