Refurbishing my '99 5th Gen

Discussion in '5th Generation 1998-2001' started by GreginDenver, Jan 13, 2017.

  1. GreginDenver

    GreginDenver New Member

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    I want to do the valve adjustment tomorrow so this evening I popped the valve covers off, got the feeler gauge set out and did a very, very careful valve clearance check. And then I double-checked my measurements... and then I triple-checked my measurements.

    Just to remind everybody, this is a '99 5th gen with 19,500 miles on it. The bike has never had a valve check/adjustment done.

    Here's what I came up with:

    All eight of the exhaust valves are within spec! #1 is 0.32mm and 0.31mm, #2 is 0.31mm and 0.31mm, #3 is 0.31mm and 0.31mm, #4 is 0.32mm and 0.32mm

    Three of the intake valves are out of spec:
    both intake valves in cylinder #2 are at 0.12mm and the left-side intake valve in cylinder #4 at 0.12mm

    Another three are very close to being out of spec:
    both intake valves in cylinder #3 are at 0.14mm and the right-side intake valve in cylinder #1 is at 0.135mm

    The remaining two are in spec: the left-side intake valve in cylinder #1 is at 0.15mm and the right-side intake valve in cylinder #4 is at 0.16mm
     
  2. GreginDenver

    GreginDenver New Member

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    Question: Where do people get shims from? Should I go to the Honda dealership?
     
  3. JZH

    JZH New Member

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    Some people collect shims over the years and build up a large collection (like me). I've heard of people sharing shim collections online (take one, leave one), but I cannot remember where I last saw that. There's also the "Hot Cams" full set you can buy if you're expecting to do this a lot. I've purchased used sets on eBay from salvaged bikes--usually they come with the buckets, which of course, end up in the bin. Some dealers (perhaps mythical dealers) exchange shims, I've heard. Or, you can buy them individually online or at any dealer. Obviously, the latter method is rather expensive.

    Ciao,
     
  4. CandyRedRC46

    CandyRedRC46 Member

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    I love when people post up actual numbers on their build. Really helps to visualize and fully understand whats going on.
     
  5. CandyRedRC46

    CandyRedRC46 Member

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    I just looked them up. I take it they are a replacement for the bt23 and supposed to be grippier but a little less mileage. The reviews were pretty good. My only experience with bridgestone was the BT23's and it was a very bad experience. Maybe I got a bad batch or something? Hopefully these are much better.
     
  6. Lint

    Lint Member

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    Trust me, the T30 EVO tires grip very well. Even at full Honda spec pressure, I rode the ****out of them and they stuck like a cat on carpet. Air them down to 34/36 per Bridgestone and they really stick. I was a PR3/4 fanboy, but I really like the T30 now. Hella sportier! Turn in is so much easier and I've never had the rear slide powering out of a turn like the Michelins did. The only time I've slid under power on the Bridgestone was on a demo of the BMW S1000XR, and that was leaned over at full throttle, but that bike is also 160hp and 83ftlb torque and I was right in the peak of it. That was also at full pressure, not aired down. I've never been able to get the VFR to spin it.

    The Michelins almost high sided me twice. Once on the track and once on the street. They'd spin out, then grip. Did a number on my tail tidy, and my shorts!!!
     
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  7. CandyRedRC46

    CandyRedRC46 Member

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    I lol'd extra hard at stuck like a cat to carpet. That is a great analogy!
     
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  8. GreginDenver

    GreginDenver New Member

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    Yesterday was mostly spent changing out the clutch internals: new Honda (OEM replacement) friction plates and pressure plates, a new judder spring and judder spring washer and I replaced the clutch springs with a set of Barnett springs.

    [​IMG]

    [​IMG]

    Barnett clutch spring on the left side and an 18 year old Honda OEM clutch spring on the right side:

    [​IMG]
     
    Last edited: Jan 25, 2017
  9. GreginDenver

    GreginDenver New Member

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    Now I've moved on to the brakes (and the clutch line too). Here's one of the first things I found:

    [​IMG]

    [​IMG]

    What we have here is the clutch master reservoir of a '99 VFR800 with 18 year old DOT 4 fluid in it. Just look at this nasty looking sludge that 18 year old DOT 4 fluid turns into as it ages.
     
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  10. Lint

    Lint Member

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    My clutch master was the same way. Nastay!
     
  11. GreginDenver

    GreginDenver New Member

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    Blowing the pistons out of the rear brake.

    [​IMG]

    [​IMG]

    Gonna replace all of the old seals.
     
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  12. CandyRedRC46

    CandyRedRC46 Member

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    Nice to see you sticking with OE plates and upgrading the springs. Top notch.
     
  13. GreginDenver

    GreginDenver New Member

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    When it comes time to reassemble the brakes the bike is going to get some Spiegler braided steel lines...

    [​IMG]
     
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  14. GreginDenver

    GreginDenver New Member

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    Slowly making progress, getting the necessary things done.

    Here are the Clutch and the Front Brake. I just finished cleaning them and installing new master piston kits. The old parts are shown below them. The old seals were pretty worn and they feel more like plastic than rubber.

    I'm especially happy to have the clutch master clean and refurbished. One of the odd behaviors of this motorcycle is what felt like a slight hesitation in "take-up" when the clutch lever was released. I think the clutch master piston wasn't bleeding off pressure as fast as it is supposed to do. Now that it's rebuilt I expect it to work like new.

    [​IMG]

    [​IMG]
     
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  15. duccmann

    duccmann Member

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    Wow wow and wow, great to see the progress. I know when I changed my clutch fluid from the factory, boy did it smell nasty.



    Sent from my iPhone using Tapatalk
     
  16. revguy

    revguy New Member

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    awesome job !!!
     
  17. Darth Vader

    Darth Vader New Member

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    This is great , you really are going through this bike properly.
    It will be like new when you've finished and worth a lot more but you'll never sell it ,
    the 5th gen whine is very addictive.
     
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  18. RVFR

    RVFR Member

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    Nice you don't see this sort of attention to so many details, good on you.
     
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  19. duccmann

    duccmann Member

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    It pays to be on the OCD side when rebuilding a bike huh J?
    Looooooking gooooood


    Sent from my iPhone using Tapatalk
     
  20. RVFR

    RVFR Member

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    Sure does. ;)
     
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