1993 ABS reccommissioning

[FJmonkey]

Bought a HF soda blaster and tried it out on the sprocket cover. Then, hit it with rattlecan engine paint.

I think the result is pretty decent.

Looking good for the rattle can...

[fj1289]

Wow!   That's shiny enough to be on Pat's bike!  Nice work

[JPaganel]

Got new throttle cables in the mail, put them on.

Then, figured I'd check valves, since I have the cover off.

Exhaust

1 .002/.002
2 .007/.007
3 .005/.007
4 .002/.007

Intake

1 .007/.007
2 .005/.005
3 .005/.006
4 .006/.006


So, I got some tight valves and I should probably fix that before buttoning up.

[FJmonkey]

Got new throttle cables in the mail, put them on.

Then, figured I'd check valves, since I have the cover off.

So, I got some tight valves and I should probably fix that before buttoning up.

Good catch, they are easy to check when the tank is off. No expensive tools and finding out of spec valves means you can prevent top end damage. Then it is an easy step to use the hold down tool and change the valves. 

[Tuneforkfreak]

Checking in on progress, did you get it running yet?

[FJmonkey]

Checking valves again after 5K miles, 3 are tight (2 EX) and 7 (4 EX) are loose. Looks like I will be checking valves every oil change till they find a stable state. 

[JPaganel]

Somebody made a paper boat from the page of the notepad where I was writing down my measurements, so I decided to remeasure and do it in metric.

Exhaust

1 0.19/0.12
2 0.18/0.22
3 0.14/0.19
4 0.09/0.19

Intake

1.0.19/0.19
2 0.12/0.14
3 0.16/0.16
4 0.16/0.16

Exhaust spec is 0.16-0.20
Intake spec is 0.11-0.15

So, exhaust 1B, 3A and 4A are out of spec, and intake 2A is borderline.

Checked shim sizes

1B 0.12 - 275 shim
3A 0.14 - 265 shim
4A 0.09 - 265 shim

2A 0.12 - 270 shim

Went to look at the chart. I am now confused.

Chart seems to indicate that for 1B I need to replace 275 shim with a 270. Wouldn't that make clearance smaller? Or am I reading the chart wrong?

[JPaganel]

After turning it around in my head, I got it. Thinner shim means more clearance. I was just picturing a tight valve wrong.

By the looks of it, I can swap some shims around, and I only need two. I will re-check the chart when I'm a little less tired.

After this, I need to bleed clutch, reinstall carbs, and get a new battery. Then, it's go time.

Although I am considering adding phone charger and heated grips before I button it all up.

[JPaganel]

So, what I need is this

1B 0.12 - 275 shim -> 270
3A 0.14 - 265 shim -> 260
4A 0.09 - 265 shim -> 255

2A 0.12 - 270 shim -> 265

I can swap two of them around, and what I really need is only a 260 and a 255

[Tuneforkfreak]

when you mess with your shims can you take some pics so I can see how it all works and goes together? I was curious how that tool functions and what it does, prolly gonna check my valves before next year and need to get familiar with the process.

[JPaganel]

when you mess with your shims can you take some pics so I can see how it all works and goes together? I was curious how that tool functions and what it does, prolly gonna check my valves before next year and need to get familiar with the process.

I'm going to disappoint you a bit - I don't have that tool, and so I can't show you how it functions.

This is what I do:



The blue thing sticking out of the motor is a piece of insulated solid copper electric wire. I bend it into a J shape and stick it into the cylinder. It takes a bit of fiddling to get it in between valve and seat. When you get it in and turn the cam, it holds valve open and I then use a small screwdriver and the hemostat to pull out the shim.

[rktmanfj]

when you mess with your shims can you take some pics so I can see how it all works and goes together? I was curious how that tool functions and what it does, prolly gonna check my valves before next year and need to get familiar with the process.

Look HERE

[JPaganel]

Yesterday the clutch was closed up and  bled.

The shims didn't quite pan out, I'll probably get them tomorrow. After that, it's close up the engine and start reassembling.

[JPaganel]

Latest news are that valve cover is back on, new plugs are in, and a set of Renntec bars has been added.

A little more work on the right-hand inner fairing panel, fix brake master wiring, reinstall carbs, get a battery, and we might be in business.

[JPaganel]

The latest work included replacing all bulbs except turn signal with LED, getting carbs in the boots, and hammering out the bent fairing stay.

Found out batteries are not the same between 86 and 93, so I'm waiting for a new battery. Once that gets here,I'll be seeing if it runs.

Also a bit of plastic sculpting.