Sunday, June 9, 2013

The Problem with Gasoline

The Tank

Upon getting this bike, I knew my first trouble area would be the fuel tank.  For those of you that don't know why leaving gasoline in an engine/engine parts for a prolonged period of time (sometimes a matter of a month or two), I beg you not to try it.  As gasoline sits, it basically breaks down into a varnish and does 2 things: rusts steel and creates a sticky, gummy solution everywhere.  The result of this on motorcycles usually becomes a rusted tank and gummed carbs and fuel lines.  This being the case, I knew I had a few things to take care of.

To take care of the rusted tank, I really wanted to try and get all of the rust out that I could.  This would ensure I had the best running conditions for the future.  After pulling the tank off I removed the petcock and fuel filter and checked to see if it held water.  I filled the tank and plugged the petcock hole and didn't see a leak anywhere so it looked like I had a usable tank.

The next step was to figure out how the hell to do this "electrolysis to remove rust."  From everything I had watched/read/heard, it really works astonishingly well to get rid of rust.  This was the way to go.  First off, I watched this video which was amazingly helpful:
So from here I needed a few things:  Some wire, big pieces of metal, a plastic tub, and "washing soda" (whatever the hell that is).  The metal and wire were super cheap from home depot.  I picked up 400ft of wire for rebar for under $4, 2-1ft pieces of rebar for just over $1 each, and a bigger metal "cleat" for $0.90. The plastic 27 gallon tub was just under $10.  The only thing left was washing soda.  That stuff is super cheap but hard to find.  I ended up finding it at Fred Meyer for just under $4.  So I got what I needed (I also picked up some wire brushes to clean things and some masking tape to label things).

The problem with electrolysis on a gas tank is that the best place to put the "rust collecting" metal pieces is in the tank... however, they can't be touching the tank.  So what I did is I put duct tape over the ends of the piece that was going in the tank.
My thoughts were that this would block the connection between the tank and the steel rod to keep the electrolysis flowing.

Next, I had to setup the tank and the gas cap that were rusted.  I brushed off a spot on the tank to ensure that the wire would have connectivity, then wrapped that wire around it.
I then connected the tank to the gas cap.  The way the electrolysis setup goes is that the parts need to have the negative connected to them, and the "rust collecting parts" need to have the positive connected them.

Next I needed to setup the rust collectors to not be touching but be able to be connected.  Kind of hard to see, but i had the tank and cap connected at the bottom (right side of the image) and the steel rebar and steel flange (inside the tank) connected at the left side (wire going across the tank).
Electrolysis Setup
After wiring everything up, I needed to add the solution.  Here, what they said I needed is water with ~1 tbsp of washing soda per gallon.  To accomplish this I used a 5 gallon bucket then filled the black tub.
Soda Wash for Electrolysis
Once filled it looked like this:
Electrolysis Setup
I had a 1.5 amp 6/12V battery tender/charger.  After running it for about 30 seconds, the charger read "trouble" meaning it had shorted or faulted.  I messed with this for quite a while and eventually determined that the steel component in the tank was causing issues.  That, and it being at 12V just didn't seem to work.  I dropped it to 6V and set the steel shank out of the tank.  As time goes on, if this doesn't yield the desired results, I will create something better for in the tank.

Moving On

Since the tank had to sit, I figured I'd move on to getting the other components on their way.  I planned on getting the carbs out since I knew there was work to be done there.  I had tried earlier just to move the throttle and no luck so I knew the carbs were stuck.

First step was to remove the airbox.
1975 CB750F Carburetors and Air Box (Left Side)

1975 CB750F Air Box


Upon removing the airbox (which was a bit of a pain in the ass), I was pleasantly surprised to see that the air filter looked almost new.  30K miles on a 38 year old bike... just not what I had expected.  Good enough, I'll leave it aside for now.

Next stop the carbs.

To get the carbs off, there were the 4 boots that mounted it to the engine.  After removing the throttle cables, I loosened the clamps holding the boots, but there was no victory there.  Being almost 40 years old, the boots were as stiff as could be.  It took quite a bit of delicate prying and wriggling to get the carbs off but I finally managed.
1975 CB750F Carbs Intake Side (From Air Box)

1975 CB750F Carbs Top

1975 CB750F Carbs Output Side (To Engine)

1975 CB750F Carbs Bottom

1975 CB750F Carbs Right Side

Now the majority of the bike will be resting on its own for a while.
1975 CB750F No Carbs, Air Box, or Fuel Tank
In tackling the carbs, I got my workbench setup, got my tools in order and prepared to commence.  One thing that may be helpful to those of you looking to "fiddle" with carbs is this video: 



This video gives a simple yet clear and detailed explanation of the basics of dealing with a carb and how it works.

So I got my carb station all set up.

Carb cleaner on hand and ready to dismantle.  Upon, taking #1 (then 2, 3, and 4) apart, I was not surprised to see what I found.


1975 CB750F Carburetor with Varnished Gasoline

The bowls and jets were all filled with gritty junk and the throttle slides and needles were gummed up with varnished gasoline.  Oh well, I got them all torn down.

1975 CB750F Carbs Disassembled

Next step is to clean everything thoroughly and reassemble.

The Beginning

So here we are.  I have a bike to work on.  I now have a bike to take and make it my own.

Lets take a look at what we have to work with:
1975 CB750F Right Side

1975 CB750F Rear

1975 CB750F Left Side

1975 CB750F Front

A 1975 CB750F Super Sport.  Everything looks like it's there for the most part.  It's a little rusted in a few places.  The bike turns over but does not run.  The controls are barely there and the right hand switches (on/off/start) are busted (the guy who I bought it from gave me a brand new one).

1975 CB750F Left Hand Controls
 Left Controls:


Upon initial inspection I noticed the gas tank was in pretty poor shape too.
1975 CB750F Tank Underside

1975 CB750F Tank Filler

Rusted Fuel Tank Opening


So taking an initial look at the bike, here's what will need to be done just to make it road worthy:
  • Revamp the gas tank
  • Rewire the right control (at a minimum)
  • Tear down and clean all carbs
  • Replace the fuses
  • Replace the battery
  • Tear down and rebuild brakes (front and rear)
My intentions over time are to not only make this bike road worth, but to go through the bike from the ground up.  This will take time, money, and resourcefulness but will surely pay off.  But again, first thing's first, the bike has to be made road worthy... aesthetics and upgrades can come later. 

In terms of upgrades, I'm not sure what I want to do just yet.  I don't think I want to just rip it apart and try to make a minimalist cafe racer; I have a 130hp sports bike to go fast on.  That being said, I don't think I'm just going to go full classic restoration either.  As it stands, my intentions are to do some modern day upgrades on things like the wiring, and controls while still leaving the classic styling.  My mind may change over time but we'll leave it up to the road ahead to determine that.

As far as the gas tank goes, I've actually had to deal with this before with the Rebel.  There are basically 2 says to deal with this:  A 3 part restoration kit which has low efficiency in cleaning out the tank, or electrolysis.  On my Rebel, I did the 3 part restoration; it worked, but knowing how it didn't take care of everything, I want to go a better route this time.  I plan on doing electrolysis to the tank to remove the rust and get it fuel worthy.

That's what the start of the project looks like.  Next post is getting into the actual work.  Can't wait!




Wednesday, June 5, 2013

The History of How We Got to Today

The Road to Now

Adolescence

Growing up, I've always had a love for tearing apart things, seeing how they work, then fixing them if I can or just putting them back together.  I also really have had a consistent passion for cars; makes, models, options, always running through my head.  From the moment I could legally drive, I virtually demanded from my parents that my first car be a manual (I wasn't spoiled, I promise).  I would drive anywhere and everywhere I could.  First in my 1988 Ford Bronco II that looked pretty much like this:
1988 Ford Bronco II
Then in my 1998 Honda Prelude that looked something like this (okay, maybe a little spoiled):
1998 Honda Prelude


College

As I went through high school, I excelled at math and science-y type things.  As a result, I decided to pursue a Mechanical Engineering degree.  During my college endeavors, I also became a member of my school's Formula SAE team.  Basically, a bunch of engineering students design, build, and manufacture a race car from scratch.  This allowed me to learn a lot about:

  • Fabrication (turning blocks of metal into functional parts using a mill and a lathe)
  • Manufacturability (that's cool, but how easy is it to make?)
  • Servicability (once you get it on, is it going to be easy to access/take off?)
  • Assembly (now that they're built, can you actually put these things together?)

The Rebel

While still in college, similarly to my demand for a stick shift, I started looking into another automotive "challenge," motorcycles.  What do I need to do to get an endorsement and a bike?  I knew as a college kid, purchasing a bike was virtually not an option.  My step-dad had a bike in the garage that I knew was sitting there so I had to begin the hinting.  In the meanwhile, I took the MSF course and got my endorsement.  Time went on and after a short while, he gave me the bike (definitely spoiled)!

Motorcycle and endorsement in hand, I was ready to roll.  Only one problem... the bike didn't run.  You see, the motorcycle, the 1986 Honda CMX450 or Rebel:
1986 Honda Rebel 450 (CMX450)

had been sitting in the garage for about 10 years with fuel left in the system; thus, my first project.  

Although in beautiful condition, I had to get it running.  The tank was completely rusted and wreaked of varnished fuel.  The fuel lines and carburetors were all gummed up.  I began the process of tearing down the components to determine the work ahead. 

The tank took the most effort.  I found a 3 step process that essentially involves throwing nuts and bolts in the tank with a solvent and rolling the around to break up the rust, then coating the tank with a sealant.  After tackling the tank, I opened up the carbs with virtually no idea of what I was doing.  I cleaned everything I could and tried to ensure that I didn't damage anything.  

After all that, I put it all back together and tried to fire it up.  After a few attempts at turning it over, it fired up!  I was successful!!!!  A quick tune up from a professional and I was on my way.

The Bug


After getting the Rebel running, I was ready to roll.  I hit the road any chance I could, weather permitting.  Even though I was 6'4" on a tiny 450 cruiser with my knees in my face, I didn't care.  There's nothing that could compare to the (cliche) freedom I got to feel on my bike.  Have to go to the bank?  Bike.  Need a haircut?  Bike.  Going the same place as everyone else?  I'll meet you there on my bike.  It was exhilarating and liberating and still a challenge.  I was hooked.

After college, I sold the Rebel and got a VFR750:

1996 Honda VFR750
Motorcycling was a new passion in my life that I would never let go.

Real Life


After having the VFR for a little while, my fiance moved up to live with me, then we got an apartment and had to plan our wedding.  Because we needed a bit of liquid cash and we were moving into an apartment with no garage, I decided to sell the VFR (this was my adult decision).

4 years went by.  We had a few different apartments, we got married, we bought possessions, got reliable vehicles, had a magnificent honeymoon (this part is key), had a couple of dogs, saved money and bought a house.  Realistically, everything was going really well and we were on a great track in life.  There was only one thing missing, those 2 wheels.

Rejuvenation


So one day, my wife and I were talking about our honeymoon (remember how I said it was key?) and she kept talking about what an amazing time she had.  We had gone to southern Florida, hung out in Miami, had fancy meals, rode scooters on South Beach, partied, then went on a cruise in the Caribbean.  One thing that she kept saying that stuck out for her was the scooter ride.  We had rented scooters for a couple of hours to just cruise and she said she had the time of her life.  She loved the openness, the thrill, the euphoria.  This led us to a discussion about motorcycles.

In a conversation about motorcycles, she said how much she'd love to have that as a hobby but riding dirt bikes.  I was all for it because 2 wheels was something I had lost 4 years ago.  After talking for a bit, and being that we live in a major metropolitan area, I convinced her that we should go the route of dual-sports instead.   By this solution, we would have the means to get to our destination with a bit of road riding, then ride a bit off road.  Additionally, I would want to commute to work and I couldn't do that on a dirt bike alone.  After the discussion, we decided to go for it. 

We did our research and found what we were looking for.  A Honda 1998 XR650L for her (that we would need to modify for her height)

1998 Honda XR650L
And a 2005 Kawasaki KLR 650 for me (not mine pictured, but almost identical).
2005 Kawasaki KLR650

We got her going and I was finally back on 2 wheels.  I couldn't be happier.  Not only do I have a wife that is okay with me riding motorcycles but she wants to do it as well!

As time went on we realized that the dual-sports were not fitting.  Too far of a drive to see anything off road, the KLR was barely stable on a 70 mph commute, the bikes were too big for any true off road activities, and the lowered XR was still too tall for the Mrs.  So some discussions were had and I started looking for alternatives.

With some searching and lots of test rides I found something that I really, really wanted.

The Adventure


Having run the trial and error of dual-sports, we came to a mutual conclusion that it just wasn't going to work.  As a result, I started looking for a bike that was really something I wanted.  I had held an endorsement now for 8 or so years.  I had fixed a bike up, rode a small, older cruiser, a sporty touring bike, and a dual-sport.  I had definitely gone through a progression, it was time for a real bike.

I started looking at liter bikes.  I thought I would never step up to that level but then putting it into perspective I didn't just jump into the deep end.  I had really taken my time and gone about things right.  I decided that I didn't want a supersport because I would still be commuting and I wanted something for all occasions.  I started looking at standard/naked bikes.  

After narrowing down the options I had a list.  There was the FZ1, CB1000R, Speed Triple, SV1000, Z1000, and a couple more like the Tuono.  I didn't like the look or the seating of the FZ1.  The CB1000R was too new so I couldn't get it for a reasonable price.  I test rode the Z1000 and, although a fantastic bike, I couldn't get over the need to wind up the inline 4 to really feel the power.  This solidified my lack of desire for the CB1000R as well.  This left either a V-twin like the SV1000 or a triple.  I test rode the Speed Triple and absolutely LOVED it.  The torque was across the board.  The maintenance cycles were few and far between.  Everything you could ever read about the bike was just gushing all over it.  The problem was that once people buy them they don't sell them.

Given the understanding that one of these was going to be hard to come by, I started looking.  Although I live in a major city, there was still virtually nothing.  After a period of time, I started to get mildly infatuated with the idea of this bike and started looking farther away.  

One day, I found a Speed Triple in perfect condition, for a really, really low price.... the only catch?  It was just under 1000 miles away.  Luckily for me I had accrued frequent flier miles from my work; not enough to do a decent trip with, but about enough to take a one way flight to somewhere less that 1000 miles away.  How convenient right?  I tell my wife about this (keep in mind I have never done anything like this before) and for some reason she says go for it (Okay, confirmed:  spoiled).  So I call the guy, confirm that it is what he says it is and told him that I'm serious.  I booked a flight and that weekend headed to my new bike.

When I arrived, the guy picked me up at the airport and took me to his place.  The bike was exactly what he said it was and made the transaction.  He let me gear up, fill up my camelbak and I was off.  Now I had just under 800 miles of trek ahead of me; just me and my new bike with about 2/3 desert and 100-110 degree temperatures.

2005 Triumph Speed Triple 1050


The journey was great and luckily no scares or mishaps.  I got to know my bike and see a few minor sights on my voyage home.  I absolutely fell in love with this Speed Triple and this is a bike I don't see myself every letting go.

Keeping the Passion Alive


Now, being a mechanical person and a motorcyclist, all I want is more.  If you've ever gotten "the bug" for something, you know exactly what I'm talking about.  There's always something more you can try, or see, or experience.  It's not that what you have now isn't enough, it's the fact that this passion infects your brain.  You think about it constantly.  It keeps you awake at night imagining what you could be doing or experiencing that you haven't already.  This being the case, I needed (by my definition) a project bike.  

I needed something that could fulfill all of those little tastes of problem solving, creativity, and success that I had attained from projects of the past; all of this while tying in with the passion that I cannot get out of my system.  I needed something that I could put my mind to and conquer, one little project and step at a time.  I needed something that wasn't easy, wasn't "the norm," and that I could feel dignified about once I had met my accomplishment.

I began my pursuit of a project bike and, similarly to my "all-fulfilling" bike (the Speed Triple), started narrowing down components and weighing pros and cons.  I wanted something old enough that it had that vintage, origin of motorcycles feel, kickstart and all.  Something that wasn't too common, but common enough that I could get parts and information for.  Something that wasn't in so good of condition that I didn't want to touch it, but complete enough that I had all the parts and could decide what I wanted to do with it as an end result.  As an outcome I narrowed it down to 2 mid-'70s models:  The Honda CB550 and CB750.

The Project 


After having narrowed it down, I searched and searched to find something in my budget that met my criteria. There were options out there, but they either just weren't right, not complete enough, too perfect, or just plain too much. 

Then, one day in my avid checking, I found the bike.  It was a 1975 CB750F.  That's the super sport model with the flat tank and the rear disk brake.  It was complete but not running but most importantly, the motor was not frozen.  I had to get it.  I called the guy, and from that point it was a done deal. We met, got the bike in the back of my truck, exchanged money and title, and I took it home.

1975 Honda CB750F Super Sport

Finally, the bike is all mine and it's time to let the project begin!!!