Got it.
Exhaust is giving me a headache. Been trying to put it back on for an hour now but never lines up. That mount in the rear keeps interfering. Took the studs out hoping it makes it easier, but not really. Calling it a day and try again tomorrow
1988 project
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Re: 1988 project
Was busy. Finally managed to put the exhaust back on.
I also connected a ground wire and ran it from coils to engine. See pics.
The coil wires were long enough after I spliced open the harness. I wrapped them in a heat resistant sleeve and ran them down.
I connected radiator and all hoses and filled it up with distilled water. Unfortunately there is a leak at one of the pipes on top of engine (sorry, don't recall the name).
Looks like I have to order a seal.
Other than that, I should be able to start her up. Since I don't have the carbs back from cleaning, I am going to use the ones off my other fzr.
Btw, I decided to just order a new fuel pump. A new battery is also on its way.
I also connected a ground wire and ran it from coils to engine. See pics.
The coil wires were long enough after I spliced open the harness. I wrapped them in a heat resistant sleeve and ran them down.
I connected radiator and all hoses and filled it up with distilled water. Unfortunately there is a leak at one of the pipes on top of engine (sorry, don't recall the name).
Looks like I have to order a seal.
Other than that, I should be able to start her up. Since I don't have the carbs back from cleaning, I am going to use the ones off my other fzr.
Btw, I decided to just order a new fuel pump. A new battery is also on its way.
Re: 1988 project
The coolant pipes will leak if they are bumped out of square in the bore. It's a very simple o-ring fitment, and usually you can get them sealed without new o-rings. (although they are dirt cheap) I typically remove the pipes, and clean the bore with a drum sander attachment on a dremel. In lieu of that a spark plug wire brush works too. Remove the old o-ring and clean it in hot soapy water. Coat it with a good dose of di-electric grease and let it soak overnight. Clean the tubes up nice and shiny with some emery cloth and re-assemble using a generous coating of di-electric grease. They'll never leak again.
I use mountains of di-electric grease in my builds as its cheap, works well for bringing rubber parts back to life, (intake boots) is very slippery for assembly, and actually is functional for it's intended purpose in electrical connections... LOL
BTW, just curious, but why move the coils out into the weather?
I use mountains of di-electric grease in my builds as its cheap, works well for bringing rubber parts back to life, (intake boots) is very slippery for assembly, and actually is functional for it's intended purpose in electrical connections... LOL
BTW, just curious, but why move the coils out into the weather?
BRS Racing #61
VRRA Competition Coordinator
VRRA Competition Coordinator
Re: 1988 project
Thanks. I had the pipes out when I swapped the engines and seals looked fine. I'll have to check again.
Yeah, not super happy about the coil placement but I couldn't find a better spot for now and never got suggestions when i asked. Happy to hear ideas. Even though I should be able to fire up the bike soon, there is still a lot left to do and won't be able to ride this one for a while. So moving the coils around is not a big inconvenience.
Yeah, not super happy about the coil placement but I couldn't find a better spot for now and never got suggestions when i asked. Happy to hear ideas. Even though I should be able to fire up the bike soon, there is still a lot left to do and won't be able to ride this one for a while. So moving the coils around is not a big inconvenience.
Re: 1988 project
Their natural placement is inside the frame rails behind the head stem.
BRS Racing #61
VRRA Competition Coordinator
VRRA Competition Coordinator
Re: 1988 project
Not on this model and year. They are normally located left hand side attached to the nose fairing stay.
Here:
I don't think I have room where you said. I checked but don't think it will fit. I'll have another look. Can you post a pic of yours?
Here:
I don't think I have room where you said. I checked but don't think it will fit. I'll have another look. Can you post a pic of yours?
Re: 1988 project
Hey, no worries. I know it's possible there and other bikes have them there. It totally makes sense, but no room on mine from what I could see. I'll have a look later, just want to fire her up for the first time. If the engine explodes, the coils are the least of my problems. Lol
Re: 1988 project
Tank after 2 days in white vinegar. Baking soda to neutralize acid, good rinse and blow dry with leaf blower after
Re: 1988 project
Coolant pipe leak is fixed. It was really just a matter of taking it out and cleaning everything.
Re: 1988 project
Next thing to tackle are the forks. One is leaking. I ordered new seals and hope I can get away with just replacing those. Thoughts?
I am hoping I can use my triple tree stand to securely lift the bike.
Brake caliper rebuild sets are on their way as well, for both, front and rear.
I am hoping I can use my triple tree stand to securely lift the bike.
Brake caliper rebuild sets are on their way as well, for both, front and rear.
Re: 1988 project
This is how she sits at the moment.
I ordered a new headlight, yay
Before it arrives and I put it on, I want to get the forks done.
After that, I can finish the wiring, which is basically everything related to the new digital cluster.
Everything needed to fire her up is already working. Really just a matter of getting the carbs back now.
So hopefully after the weekend, everything that's left are the new sprockets, chain and tires (which I still need to buy as soon as I have money for it).
And oh yes, finish the tail piece plus tail light and some turns front and back.
I ordered a new headlight, yay
Before it arrives and I put it on, I want to get the forks done.
After that, I can finish the wiring, which is basically everything related to the new digital cluster.
Everything needed to fire her up is already working. Really just a matter of getting the carbs back now.
So hopefully after the weekend, everything that's left are the new sprockets, chain and tires (which I still need to buy as soon as I have money for it).
And oh yes, finish the tail piece plus tail light and some turns front and back.
Re: 1988 project
So I took off all brake calipers and will rebuild them this weeekend.
At the same time, I am trying to figure out how to lift the front to remove the forks. One is leaking and I want to replace the seals on both.
Exhaust:
I need a new muffler. I have a kerker on my other bike and like it, but nowhere to be found. What are other options?
Or even better, I'd like to put on a 4 into 2 system on. Is there a system that would fit without big modifications?
At the same time, I am trying to figure out how to lift the front to remove the forks. One is leaking and I want to replace the seals on both.
Exhaust:
I need a new muffler. I have a kerker on my other bike and like it, but nowhere to be found. What are other options?
Or even better, I'd like to put on a 4 into 2 system on. Is there a system that would fit without big modifications?
Re: 1988 project
Is it safe to jack up the bike by those engine mount rails for a week or so?
Need to take the forks off.
Need to take the forks off.
Re: 1988 project
Some progress...
I took forks and both wheels off for tire change and fork rebuild.
Wheels will be painted before they go back on. I also had to replace the RH clipon because it was bent.
I am a bit confused and concerned about the steering bearings. The old ones were shot. When removing them, those rings (forgot the name) pretty much fell out of the neck. They should be a tight tight fit. Even the replacement ones barely stay in place. Not sure what's going on but I'll use bearing mounting loctite to keep them from spinning.
New sprocket, new wheel bearings, new pirelli angel gt tires
Cut off ignition mount to make room for my trail tech. Ignition switch will be relocated, not sure yet where to. Trying to reuse the existing one even though it's pretty big. If I ran into issues in regards to room for it, I will buy an aftermarket one.
I also shaved off the two mounting points on the neck to allow the headlight to sit closer to bike. I have one off a v-rod. I ordered a dual headlight before but didn't like it.
Cleaned up brakes
I took forks and both wheels off for tire change and fork rebuild.
Wheels will be painted before they go back on. I also had to replace the RH clipon because it was bent.
I am a bit confused and concerned about the steering bearings. The old ones were shot. When removing them, those rings (forgot the name) pretty much fell out of the neck. They should be a tight tight fit. Even the replacement ones barely stay in place. Not sure what's going on but I'll use bearing mounting loctite to keep them from spinning.
New sprocket, new wheel bearings, new pirelli angel gt tires
Cut off ignition mount to make room for my trail tech. Ignition switch will be relocated, not sure yet where to. Trying to reuse the existing one even though it's pretty big. If I ran into issues in regards to room for it, I will buy an aftermarket one.
I also shaved off the two mounting points on the neck to allow the headlight to sit closer to bike. I have one off a v-rod. I ordered a dual headlight before but didn't like it.
Cleaned up brakes