Project CBR600F: Getting into the wind!

Yesterday, with some more garage time scheduled and the carbs reassembled (sorry forgot to take pictures of the fancy metal fuel T), it was time to test ride again.  The idle stayed stable now that the adjuster had the tension spring installed.  The stutter/surge/stumble was still present around 5.5K through about 6.2K. If I powered through it, or ran the bike higher in the RPM range, it did much better.  Hmmm... sounds like the pilot (aka fuel mixture) screw needs to be adjusted.  When rebuilding the carbs, I set it to factory spec, 2.5 turns out.  However, this bike has a K&N air filter, and a full Delkevic exhaust system without a baffle.  So, that may require some adjustment.  

Out in the real world, running errands. Leaky fork seals and all.

Your handsome author and human safety cone!

I thought I was running the RPMs high (around 7K), until I checked the stock tach. 

Later that night, I drained the carbs, pulled them and loosened the bowls so I could adjust the pilot screws.  This being an 80s bike, the mixture screws have limiter caps to keep people from fiddling with them and cocking up the delicate balance set to meet the EPA requirements. It takes a torch and time to remove them, so I just pulled the bowls instead. 

I'm not sure how Honda expects a person to adjust these while the carbs are on the bike, and it's running. Rumor has it, there is a Motion Pro tool that you can use, but you can't have the limiter caps.  Since I already turned the screws out to 3 turns, from the stock 2.5, I'm just going to do some test rides and see how it runs.  If it needs further adjustment, I'll probably pull the limiter caps. 

As you can see from the errand pic, I'm still riding with leaky seals.  The parts haven't arrived yet, so I'm making do. It's not terrible but it will definitely be better with some dampening! I noticed under heavy braking, my oil cool rubs my front tire.  If that continues after getting the forks to spec, I'll have to make a new mount. 

**UPDATE**

Tried a test start today and there's still fuel coming out of 3/4 overflow.  This stopped when I balanced the carbs yesterday but didn't seem to let up today. I'm going to pull the carbs, check all the jet sizes, check the float valves, and replace the floats with a set from my donor carbs. I might actually just test them on the rack this time.  

Tools For The Road

 I like making functional tool kits that skirt the idea of being minimal.  Unfortunately, I tend to ride ratty old bikes that squeak and leave droppings.  So, I over prepare. Here's what I currently have packed for the Hurricane. 

For the recent repairs and mods, I've been trying to use only the tool kit. That way I know I have what I need when I'm out riding. I thought about carrying the full socket set and may do so, just in case someone else needs assistance.  

Project CBR600F: Missing Bits, Broken Bits, Messy Bits

 The headlight bucket print failed about 24+ hrs into the print job.  I missed a setting in the slicer program which resulted in lines crisscrossing the open spaces. Upset at first, but lessons learned. 

In regards to the weird dropping idle issue, after consulting some moto friends, one suggested my idle adjuster may physically be adjusting itself, in addition to the minor vacuum leak.  So, I checked my donor set of carbs and saw this. 

My set is missing the tension spring! Which, when I stopped and thought about it makes sense.  With how much I had to adjust the idle, it should have been damn near screwed all the way in or at least close but it wasn't.  

When trying to remove my carbs, which was more difficult than in the past, they popped off with some force. The tiny little dirty metal colored spring went for a vacation in my garage; only to be found when I gave up hope and went to search for a suitable replacement.  With that crisis resolved, I noticed my carbs were sitting crooked.  Well, apparently, I was too damn ham-fisted to work in the garage that night.  I snapped the plastic fuel T between the carb banks. 

Thankfully, I found a metal version on eBay.  So, it's kind of a happy accident, which gets me an upgrade. I tried to remove the one from my donor carbs, but most of the screws are stripped so badly I couldn't get them out, even with my fancy JIS screwdrivers. No worries, the new piece should be here Friday; and I still need to get dielectric grease for the carb boots.  

I did manage to print a fork seal driver, which is pretty cool and saves me $40. 

Stay safe out there. 

Project CBR600F: Less Leaks, More Test Runs!

 I started the day off by verifying spark on cylinder 3.  It looked fine, after I reseated the plug wire into the coil, repeated that for cylinder 2.  With that done, it was time to get some fresh fuel.  Test tank hooked up, bike idling to running temp, time to bust out the super fancy CarbMate electronic balancer.  

So far, it's been holding it's fuel, and the coolant leak is pretty minor so it will get resolved once the current host of issues is resolved.  The balancer is super easy to use, so I was done in no time.  Probably should have taken pictures.  With a somewhat proper running motorcycle, I geared up and took her out for a spin.  A few times while out, I had to turn up the idle.  Once on the way home, the bike stalled when I pulled in the clutch.  When starting it up again, the idle was low.  I thought I may have lost cylinder 3 again, so I headed home to temp check.  Ran fine on the way home, and all 4 were firing.   Time to go back out! 

On my last run, had to adjust the idle again but it didn't die this time.  It did however, develop a surge, or stutter around 5K rpms.  I brought it home and parked it. Did a spray test later, and found a leak around carb 1.  The carb boots are new, as of 2019 but I ordered a replacement set anyway.  The fork seals are on the way too.  Found out I can print a fork seal driver, so I'll be doing that once my headlight bucket is done printing. 

So, we're making progress and damn it was good to get out on two wheels, even just for test rides.  It runs strong and is damn nice too ride.  Will be even nicer when the forks don't bottom out! 

Project CBR600F: Oh! Rings and the Spaghetti Factory

 I ordered a set of OEM o-rings for the fuel T, which are damn near impossible to find.  Which seems to be the case for a lot of the first gen parts.  For example, the o-ring for the water pump is rarer than bigfoot. Some guys on a Hurricane page gave me a link for an o-ring supplier who carried an OEM spec ring for the fuel T.  I paid about $20 with shipping for a set of 2 OEM, and about $12 for a pack of 50 for the aftermarket OEM spec.  

**UPDATE** OringsAndMore just got back to me and have a suitable item for the water pump. I ordered a few so I'll have spares. ****

One of these things, is just like the other, but cheaper. 

                                                    

In other news, I managed to print a set of plate mounts.  Did I mention I got a 3D printer?  Well, I did and it's pretty damn cool (when it's not pumping out plastic spaghetti).  I also printed a cramp buster a few weeks ago. 

Radioactive Cramp Buster!

Mmmmm.... sketti! 

Excellent, al dente! 

I have a few other parts that will be printed, handguards, head light ears, switch mounts, and maybe a new gauge cluster with a sun shield.  The material is PETG, which is like ABS but without the nasty VOCs and sensitivity to drafts. I found a cool tool box but with how long it will take to print, I may just buy a tool tube.  

Stay safe out there!