G'Day all new member doing 4th gen rebuild

Discussion in '3rd & 4th Generation 1990-1997' started by kevb, Jul 9, 2010.

  1. kevb

    kevb New Member

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    not sure if right section, feel free to move or chastize me as required

    After a pretty big off I have decided to rebuild my bike, I thought you guys maybe interested in watching the progress (and adding any ideas or suggestions as I go). I will try to post as many pics as possible. the first thing i did was get her home
    [​IMG]
    pulled the side cover off and found the clutch was stuffed, in my hand is a piece of the clutch. Those of you with keen eye sight will also notice the crack in the starter clutch outer just to the left of my hand
    [​IMG]

    so replaced both the clutch plates and the clutch outer, hell she has 117546 k's on her something needs to go eventually.

    decided to replace gear selector at the same time as it was getting a bit sloppy due to the teeth being worn down (two week wait for that so figured bugger it I will clean her right up) so this is how she sits this afternoon.
    [​IMG]
    [​IMG]
    didnt realise how hard it is to source fairing for this model, I am going to try and fix the majority of the fairing myself but if any one can steer me in the right direction for new/aftermarket stuff I would be greatfull (especially the left upper)

    Kev
     
  2. karazy

    karazy New Member

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    Welcome to the forum Kev. Nice...er...bike.

    You are a brave man for taking on a project like this. With that kind of mileage, I would hope you have some kind of history with this bike. From the pics, it doesn't look they were kind miles. The colour of that oil alone, makes me shudder. Hopefully it is in better shape than it appears to be.

    There are links on this site for the replacement fairings. Let the search tool and Google be your friend. If don't already have it, the service and common service manuals are available on this forum, as well.

    I wish you the best of luck in this project and hope you have many happy miles on her yourself.

    :crazy:
     
  3. kevb

    kevb New Member

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    I have had the bike for 4 years, when i bought her she had 67,000 k's on her, so yea i have put alot of k's on her myself this is what she looked like when i first got her
    [​IMG]
    as for the colour of the oil that was the oil that had clutch pieces mixed in with it.
     
  4. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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  5. kevb

    kevb New Member

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    spent the evening tonight out in the garage and started to weld the pieces together, over the course of this week I will be buying ABR plastic cement to fill in the gaps, then smooth it all back and get her ready for painting. Here are the progress pics
    the first 2 pieces
    [​IMG]
    welded together
    [​IMG]
    strength test
    [​IMG]
    the second 2 pieces
    [​IMG]
    and welded together
    [​IMG]


    What this doesnt show is the many cracks in the fairing that I welded together as well, and with the 2 big welds together I am thinking about running some fibreglass behind them for extra strength (any thoughts on this would be welcomed). Two of the lugs are missing of some bits some I am also thinking of making a mould out of the other lugs and building new ones with the ABS cement, will see how I go!
     
  6. Big3

    Big3 New Member

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    My first suggestion would be to clean that garage.. I hate working in clutter

    maybe clear those shelves & use them for part storage


    as for the project good luck & keep the pics coming:)
     
  7. drewl

    drewl Insider

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    Welcome aboard.
     
  8. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    I used an old piece of fairing from the junk yard. Took my plastic welder to heat up/mold and form in the missing pieces I needed. Then welded into place.
     
  9. thepimpdaddy

    thepimpdaddy New Member

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    In welding plastic, I read somewhere that small strips of aluminum roof flashing across the broken joint, when bonded with your welding epoxy, will give sufficient strength to keep it together. I did some fairing repairs along the lines of what you're doing using hints from this site (I used PlastAid epoxy - wonderful, strong stuff!) and it's worked out great, a lasting strong bond!

    Best wishes
     
  10. kevb

    kevb New Member

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    I thought I had better do a quick update, I decided to put the bike back together today and see if it all still fit. I know that it doesn’t look pretty yet but I will eventually get there, I need to find the paint codes for the bike now as I am up to the stage of bogging up the plastics and getting them smooth so I can put the paint on her, she stills needs a lot of work but I needed to see what it was coming up like just to keep my enthusiasm up. I am thinking about changing the colour all together. Any input is more then welcome.
    [​IMG]
    [​IMG]
    [​IMG]
     
  11. crustyrider

    crustyrider New Member

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    cool....nicely done....I say keep her red....
     
  12. crynsie

    crynsie New Member

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    Paint code

    From memory, the paint code is on a sticker underneath the seat...

    I believe the red is standard hond red, most bike panelbeaters will be able to get it for you.

    Also, have a look at David Silver Spares - HOME They have a lot of stuff and the prices are very competitive. they also have fairings if you need them.

    I didn't do a full colour on mine and I am really happy with it.

    Have fun!
     
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