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Old 03-11-2010, 10:41 AM   #61
justplainray OP
ucancallmeray
 
Joined: Apr 2009
Location: jolly old New England
Oddometer: 255
thermostat

I think that after 20 years of service the old thermostat could do with replacing.
Honda wants $32 for a new 'stat, but a car thermostat is less than $9.
Also Honda does not spec the temp at which their 'stat opens, and I wanted to know that number.
Automobile 'stats are supplied with that temp specification.
So I took the thermostat and housing down to Advanced Auto where I was allowed to
open box after box until I found a 180F 'stat that would fit the housing.



Well it sorta fit....



While the overall height of the new one was less than the old one.
The height of the new one from the flange to the top is actually taller than the old one.
But other than that it fit the housing socket just fine.



So....what to do???
Make up a spacer plate from 3/16" thk aluminum. Use a gaaket on the bottom side and the OEM O-ring on the top.



And.....vah-lah...



like it was made for it.
Well, almost like it was made for it....you'll notice in the third photo there is a small hole in the flange of the new 'stat.
That hole was not there on the new 'stat originally, but the old 'stat did have a hole, I had to drill that one myself.
The hole is an air bleed to help with filling the system.

Happy to report the new 'stat works like a champ.

stay tuned,
justplainray
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Old 03-11-2010, 02:52 PM   #62
mas335
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Well Honda's shop manual can give you the thermostat opening information, page 5-4. 176-183 degrees.

It's a good idea to change it out, I had a bike that always ran cold and was sure someone removed the thermostat, once inside I found what 20 years of metal fatigue can do.
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mas335 screwed with this post 10-03-2010 at 02:28 PM
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Old 03-11-2010, 05:48 PM   #63
justplainray OP
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the shop manual....

who would of thought of looking there?
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Old 03-11-2010, 06:14 PM   #64
DADODIRT
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I'm in.
Cool project.
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Old 03-12-2010, 12:32 PM   #65
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Quote:
Originally Posted by Blackbert
Hey Santa,

Yes, I remembered you did use 2 pods.

Any chance you can give us the numbers for the jetting changes you had to make (stock - new)? I'm thinking of going that way as well, I've been lucky with the OEM filter once and those would give about 20cm more "clearance" I think.

My jetting wont work with stock engines. I'm running the 700 Hawk engine.
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Old 03-12-2010, 02:11 PM   #66
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I know, but I'm still a noob when it comes to carbs and how they realy work.
So my virgin mind was thinking: i.e. main jet from 155 to 157, could be the same range needed on the 600 engine. Or it may be not that simple.
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Old 03-12-2010, 03:01 PM   #67
Santa
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I dont have the numbers in front of me at the time but my jetting is pretty far from stock. I dont think a stock 600 would benefit from the jet kit I have.

Have you looked at the Dynojet kit for the TA?
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Old 03-23-2010, 03:30 PM   #68
justplainray OP
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well spring has sprung....

its been a little while since I last posted, so heres whats new.
Procured a Corbin seat, thank you very much D L White.






Its in great shape, and I'm happy with it.

Sandblasted the AT fuel tank, primed it black with POR-15, then mounted tank and seat to the bike.





The AT tank and the TA seat don't match too good. I'll run it this way this year...but I'll have to come up with a plan next winter.



Major Gap-osis...

Laid out the fuel pump/filler/lines etc, etc, Went with the vaccum fuel pump mounted with the left side coolant pipe screw.
The filter is a car fiter, it has an inlet, outlet and a return port. As I have two fuel tanks, I plumbed the axuliary tank
to the inlet port (directly opposite the outlet) and the main fuel tank to the return port on the side of the can.
The return and inlet are both on the "dirty" side of the filter element. Gas from either tank must pass thru the filter element
before exiting the outlet port on its way to the fuel pump inlet.
And yes, that is a lawn tractor fuel shut-off valve, a regular petcock would not fit.



Also mounted the GIVI bars from Twisted Throttle...not too much profanity was required.
Next, I mounted the OEM radiator grilles and fashioned side panel templates out of cardboard.
I'm debating whether these should be aluminum or plastic sheet stock.





The skid plate and axuilary fuel tank are due back from the welder this week.
I've got the tank filler neck and mounting hardware already to go.
Mocking up these pieces in cardboard is a real help when working out details.



Mounted up the hacked up battery tray.



Well that's about as much damage as I can do today. Weathers great, I think I'll take a ride.



Ah-oh...dead battery...



Well, darn.

stay tuned,
justplainray
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Old 03-27-2010, 05:37 AM   #69
justplainray OP
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hey, check it out.....

looky at what the welding shop delivered.





three and a quarter gallons (US) of dual sporting pleasure.
let's see how it fits.















I love it when a plan comes togerther.

The rear rack will require a flip-up feature to access the fill neck.
Not the most convenient when loaded, but better than loose gas cans.



Now I need to design racks for the panniers and muffler hanger.
Finish up the headlight/speedo area, fabricate the radiator shrouds, add turn signals, mount skid plate......
and Bobs your uncle.



stay tuned,
justplainray
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Old 03-27-2010, 07:39 AM   #70
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Old 03-27-2010, 12:35 PM   #71
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Awesome! Just PMed you some pics!!!
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Old 03-27-2010, 03:16 PM   #72
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Ray me Ol' Mucka,

Outstanding!!

What are you going to do with the seat?

Cheers,
Tricky
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Old 03-27-2010, 05:02 PM   #73
justplainray OP
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what to do, what to do.

Quote:
Originally Posted by Archangel007
Ray me Ol' Mucka,

Outstanding!!

What are you going to do with the seat?

Cheers,
Tricky
I think, with the upholstery removed, I can slice the fiberglass base into strips and
flatten the front section, as viewed from this angle, to get the seat and tank to match.


Then re-glass the base and re-upholster with the same cover material.
But I won't try that until next winter, as the riding season is almost upon us and I'm running out of time.
I'll be sure to post photos of the fiasco for all to enjoy.

stay tuned,
justplainray
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Old 04-03-2010, 05:08 PM   #74
justplainray OP
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tanks are done....

just got these back from Line-X on April Fools day.




Spent Good Friday (isn't every Friday "Good Friday") mounting the tanks, plumbing the fuel lines.



Mount the CDI boxes....





I love the look....Real Apocalyptic......Trans-Apocalyptic.

stay tuned,
justplainray
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Old 04-04-2010, 04:56 PM   #75
Willis24
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Quote:
Originally Posted by justplainray
Modeled it up in SolidWorks 3-D,
Any chance you can share the SolidWorks file with us?
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