Set-up new grinder, assemble lowers

Bought a mid-range Delta 6″ bench grinder, wire, buffing, polishing wheels at Lowe’s.

Progress today

Assembled and experimented with wire-brushing some bolt heads and shifter pedal.

Also found two lovely stainless steel socket head machine screws at Lowe’s to replace the rusted phillips heads in the lower fairing.  Got the second screw out; turned with big jaw pliers. Cleaned surviving fairing half and new one. Reassembled with new screws.

Ordered OEM air filters and overflow bottle, as determined yesterday.

Picked up new battery – already filled and charged – better get moving on this rebuild. Also fuel filter and other supplies.

 

Begin teardown, evaluation

Began disassembly with some evaluation. See checklist (V2). Photos and notes for later reference on reassembly.

Items determined to need replacement today:

  • Coolant overflow bottle – brittle, broke apart at touch. Hose from radiator left in place, ok.  Drain hose in bag with tiny hose clamps, also ok.
  • Air filter – not just very dirty;  oil/grease through at least 50% surface. May attempt, but probably not worth cleaning

  • Pre-(air) filter element – it had crumbled to gel/slime

Progress today

Removed lower fairing ass’y.  Cleaned up the mounting bolts/rubbers and left on the frame points.  Need to separate fairing halves to replace rashed right one.  Both screws solidy rusted in.  Used penetrating oil.  Got one off, 2nd still stubborn. Try again tomorrow.

Removed coolant overflow bottle.  

Removed tail section fairing ass’y.  Disconnected rear light wires at harness:

Grab bars already off – need polishing.   Both rear plastic tabs at main bolts broken off. Will have to weld/repair the left half plastic we’re keeping.

right
left

Parts marked L and R, in bag with bolts and cushion washers, which look good.

Removed gas tank with hose and fuel filter attached.

Original fuel filter location - line to carbs from fuel pump below
hose locations under tank; larger is breather drain
small diameter hose sticking up goes to fuel tank. Note also position of main fuel hose to carbs (on left) and breather to airbox (upper center)

Pulled out tank breather/drain tube from bike frame:  has chewed or cut parts. May replace. Tank may still have fuel in it.

Disassembled and removed airbox ass’y with sub-filter attached.

looking forward at sub-air filter housing with hose attached

Note: one of it’s mounting screws is mostly hidden at front under forward breather tube attachments.

Inner screws are captive. Rear-most/lower (3) screws have cap and sleeve.

Removed battery and tie-wrapped wires for each terminal. They appear to be original bike wiring + alarm circuit + charger plug.

as-wired before removal

End-of-day

 

Project overview

I bought my 1994 Honda VFR750F in 1997.

I commuted daily to work, and took several road trips through 1999.  In that year I slid it on its right side after locking the front in a low-speed panic turn.  Other than a failed battery, loose turn signal, and the obvious body and lever scrapes, there was no serious damage.  I replaced the battery and bought some new right-side body panels, but did not install them.

I rode regularly for a few more months, but then stopped commuting on the bike, having a new job downtown convenient to the Metro.  Some time in 2002 I stopped riding altogether, and the bike  has been parked, unridden since.

It’s time to do a decent renovation and get this beauty back on the road.  Here she is, in the new garage (minus mid-fairings, which are stored away in good condition):

I inventoried the bike and drafted a checklist [V1] of tasks, tools, and materials.  I’m using that to log purchases and track work progress.

Highlights of work planned:

  • Clean/rebuild fuel system:  carbs, fuel paths, tank, petcock, cables, controls
  • Clean/rebuild brake and clutch master cylinders, brake calipers, clutch slave
  • New: stainless braided brake and clutch lines
  • New: brake pads, oil/air/fuel filters, fork seals, spark plugs, tires, slip-on silencer, grips
  • New, as needed: Rectifier/regulator, thermostat, thermosensor
  • New: coolant, engine oil, brake/clutch fluid, fork oil
  • Clean/lube: chain, wheel bearings, steering head bearings, center stand, side stand
  • Inspect/replace any brittle rubber hoses, wiring
  • Check exhaust system for rust/leaks
  • Clean/polish: engine covers and frame parts, windscreen, meters, swing arm, wheels, etc.
  • Repair/replace/repaint: upper right, lower right, right rear fairings and seat cowl (tabs); coolant overflow bottle, right front turn signal, foot brake pedal/driver right foot peg

It’s likely I’ll find more things wrong during tear-down and as I open bits.  But this is the starting point.  On we go …