Flooding Fireblades: Sorting the fuel system on a '97 CBR900RR

Butterfly is under-gasoline...

Weather's closing in on us up here in Canada.  I had the 'Blade up on the bike lift last week thinking the riding season was over as we got buried in our first snow storm.  The next week suddenly warmed up due to a tropical storm somewhere, so I primed the Honda and got it going again (I'd run it dry in preparation for winter hibernation).  Unfortunately, it flooded itself and ended up with the first two carbs full of fuel.  You can see the wet in carb bell on the left.

I think from now on I'm going to turn off the fuel tap from now on whenever it's sitting rather than trust this touchy carb set to do the right thing.  Instead of taking the Fireblade out for a weirdly warm ride on Sunday, I was sitting on the driveway removing the carbs and changing the oil.

On the upside, pulling the carbs gave me a chance to replace all the rubbers (airbox and engine side), which needed doing (I'd been holding them together with some cunning chemistry).

New rubber bits on old bikes make a huge difference.  Even the engine side ones (which still looked good after 23 years of service) were hard and unyielding compared to the new ones.  I'm curious to see how the new ones seal in comparison.  I got the airbox rubbers from KW Honda in Waterloo, who were very responsive on email which hasn't always been my experience with local dealers.  They got four rubber airbox boots for a 23 year old bike that's been out of production for decades in less than a week, during a pandemic.  It's good to know my local Honda dealer supports older models.

I picked up a second carb set from NCK Cycle Salvage in Woodstock last fall for less than the price of the broken bits I needed to replace on the one that came on the bike.  I now have an entire second set of carb hard parts I can go to if I need any other bits.  The set they gave me (other than needing a choke pin on one of the carbs) was complete and balanced, and when I threw it on it worked a treat, so I ran it all summer having never gone through it.

With the carbs off in the late autumn sun last Sunday, I finally took the float bowls off and discovered that they were pretty grotty (when I emptied them the fuel came out brown).  It didn't take long to clean everything up, and I got carb cleaner deep into the jets and upper parts of the carburetors too.  It all went back together nicely and I was also able to lubricate and clean up the throttle action with the unit out, though it already moved sweetly.

With the new rubbers on, I put the carbs back on after work this week and they came back together nicely.  It's a good idea to attach the two throttle cables to the carb set while it's still loose.  Once the carb set is on the bike getting the cables on is a real bugger.

I went over all the fasteners as I went making sure everything was snug and leak free.  I've still got to put new oil in it, but we have a above zero day this Saturday so I'm hoping I can take the 'Blade out for an end of year run to make sure everything is five by five before I hibernate it for the winter.  Months hence after the winter of second-wave COVID pandemic, the Honda will be ready to go with fresh oil and a clean and capable set of carburetors.

This forgotten Honda is a real treat to ride this summer and is a very different thing from the Tiger.  One is a long distance tool built for pretty much anything, the other is more like an aeroplane designed for the road.  The 'Blade weighs over 20% less than the Tiger and makes almost 40% more power.  On interesting paved roads the Fireblade is in a class by itself.  Unfortunately, I live in a place deficient in interesting roads and track days in Ontario, even when there isn't a pandemic, are needlessly complicated (you basically have to show up with a race bike or rent something, there are no ride-on days for road bikes here).

The other nice thing about the Honda is how it's built for a single intention.  That focus on light-weight means getting in to work on it has been accessible and enjoyable.  Honda's aren't just designed ot run well, they're designed to be worked on too.  As my first Honda this bike has been a positive introduction to their engineering and design philosophy.

If I lived somewhere with interesting roads and reasonable track days I'd be hanging on to the Honda indefinitely as it was designed to express the dynamics of riding, but living in South Western Ontario, devoid as it is of interest, means I'm going to try and move the Honda on in the spring... assuming anyone is left post second-wave to buy it then.  I'm going to miss what it can do though.  Having this bike has opened my eyes to what a motorcycle is capable of dynamically.

FOLLOWUP

We've got a major winter storm (100km/hr+ winds, rain and snow mixed) rolling in, but I got out yesterday afternoon for an hour and the 'Blade is even sharper than it was before.  The new rubber seals tighter, making the engine even more responsive, and the cleaned carbs are razor sharp in responding to throttle.  When I got home (cold, it was only a degree or two above freezing), I closed the petcock and ran it dry before parking up the 'Blade and wrapping it up for the winter.

After our long cold winter with second wave COVID19 piled on top, it'll be ready to go in the spring...

Athletic Intent

Coming to terms with the Fireblade...

The first couple of times I rode the Honda I found the riding position hanging over the gas tank somewhat extreme.  The bike was astonishingly light compared to others I've ridden (dirt bikes excepted), and changes directions like it's telepathic, though the clip on handlebars mean you don't get a lot of leverage when turning.

While the riding position is pretty extreme compared to the adventure and sports touring bikes I've ridden recently, it's the bike's geometry that really surprises.  The rake on the front wheel is nearly vertical, and feels like it's right under your hands rather than stretched out in front of you.  This results in those telepathic direction changes.

I've actually jumped on the Fireblade and had my groin seize and had to stop to stretch.  I've taken to doing some limbering up, Zombieland style, before I get moving on the Honda.  It's nothing that a bit of yoga doesn't address in my 50 year old self, but the 'Blade is an extreme thing that demands physical interaction; it reminds you that it's a SPORTS bike.

So, why be uncomfortable?  It might be argued that the CBR900RR is an appearance bike; something you put on to get attention, but that isn't why it's the way it is.  The 'Blade is built to explore the physical limits of what a motorcycle can do - it's the opposite of a cruiser, it's about the sport of motorcycling, not the appearance.  Every choice on the bike, including the riding position, is designed to maximize speed and agility.  The 'Blade is more of a boxing boot than a high heel.

1997 Honda Fireblade CBR900RR

by timking17

on Sketchfab

One of the most shocking things about riding the Fireblade is its acceleration.  I've yet to own a bike where I can't turn the throttle to the stop opening it up... until the 'Blade.  It's so light it pulls strong through the first sixty-five hundred RPMs, but then it lunges to the redline in a startling manner.  Even in higher gears I haven't turned the throttle to the stop yet.

The CBR900RR is described as a bike that is engineered to exceed your abilities but is accessible enough to show you how to improve them, and that's just how it feels.  As someone who has gone out of his way to explore motorcycling, it checks a box for yet another aspect of the sport to discover.  I won't be putting big miles on the CBR, but they'll be highly intentional and informative ones.

COVID19 Rapid Restoration: Fireblade for the first time since Obama was President

The Fireblade project has come together nicely thanks to the strangeness we all find ourselves in with the COVID19 pandemic.  With a suddenly extended March Break, I was able to sort out the fairings, get the LED indicators wired up and finalize all the plumbing for fuel delivery.  It was all fiddly, last minute stuff, but with the time in hand it was easy to sort.  The adjustable indicator relay got wet when I cleaned up the bike which prevented the LEDs from flashing, so it got waterproofed and sealed.  The first ride was enlightening...

360° Video from RICOH THETA. - Spherical Image - RICOH THETA

That's the first time it's been running since Obama was in office.  It's a very different thing from other bikes I've owned.  I'm a big guy and 50 years old, but the yoga helps with the flexibility needed to ride this machine.  The foot pegs are significantly higher than anything I've owned before, and I'm leaning forward over the gas tank in a much more prone position than on the Tiger.  I was very conscious of the clip-on handlebars and the lack of leverage you have when cornering - steering on an adventure bike is much easier because you've got big, wide bars that offer a lot of pull.  The Fireblade was so much harder to turn (the weight of leaning forward doesn't help) that I actually thought the steering was obstructed, but it wasn't, it's just a lack of leverage.

After the first ride I thought, 'this thing is virtually unrideable!'  But as I was working out the details and getting used to it the riding position started to make a different kind of sense; I think this bike can teach me things.  The centre of gravity is so low, and the bike is so much lighter (over 40 kilos!) than my Triumph Tiger, while producing thirty more horsepower, that it's a significantly different riding experience.  I wouldn't want to go touring with it, but for an athletic afternoon out on nearby twisty roads, it's the instrument of choice.

The inline four cylinder 918cc engine makes a glorious noise when you crack the throttle, and the 'Blade is responsive in a way that makes any other bike I've ridden feel heavy - that's something I could get used to.  On subsequent rides I got my legs into the cutouts on the tank and once locked in place the whole thing suddenly clicked.  It'll take all the core work I've got to work with it, but this machine expects you to take riding as a sport rather than a leisure activity.

So far I'm at $1200 for the bike delivered, $250 in taxes and registration, $280 for a replacement carburetor which I cannibalized with the one I had to create a working one (if anyone needs late 90s CBR900 carb parts, get in touch), and another $200 in parts that included the shop manual, oil and filters and the LED lights.  All in I think I'm at about $2000 on the road and running like it's new again.  Looking up CBR900RRs online, a one a year older model with three times the kilometres is on for $2800.  Low mileage mint ones are going for $6-7000.  I think I could sell it in a year for a thousand more than I put into it.

When the pandemic happened here just before March Break I took home the Structure Sensor 3d scanner and did some scans, which is what you're looking at here...

1997 Honda Fireblade CBR900RR

by timking17

on Sketchfab

It's very satisfying to bring the 'Blade back to life.  Now that the mechanicals are in order I'm thinking about racing stripes.  Amazon has some well reviewed ones on for a good price, I'll give them a go rather than painting them on.

Unfortunately I'm stuck for getting the bike safetied and registered on the road because everything is closed at the moment.  I'll spend the time making sure everything is order and looking to the aesthetic details and hopefully I'll be able to put the bike on the road when we put society back in motion again in May.

Fireblade Petcock

I think I've finally gotten the fuel system on the scuppered Fireblade sorted.  The last problem (and probably what caused all the other carb and engine issues) was a leaking petcock.  I tried to take apart the existing one, but I should have listened to the Chilton manual and just replaced it in the first place.  The new one (40 bucks on Amazon) seems a quality thing.

The petcock in the tank was pretty mucky, and was leaking even when turned off.  If it was pouring gas into the carbs all the time, even when parked for long periods, it must have filled up the carb bowls and spilled over into the intake manifold and eventually found its way into the engine oil, which would explain the seven litres of what looked like muddy water that came out of the oil drain plug.

The new petcock looks like a more finished thing than what was on it.  Based on the questionable mechanics on the rest of the bike, I'm guessing this was just something that fit rather than the right spec part.  The one on the top is the new one and the bottom one was what was on the bike.  It seems odd that Honda wouldn't actually tell you what the petcock is doing by writing the position on the thing.  

The old one also was also lacking the fuel filter, and the new one with the filter on it wouldn't fit throught a tube stuck up in the tank hole.  I removed the old o-ring and managed to free up the tube with some WD40 and slide it out.  Like everything else I've found in the fuel system, it was a pretty mucky thing.  With those weird bits now out and the tank cleaned, that's the whole fuel system sorted, so hopefully it'll run like it should when I finally get the tank back on.

The goal now is to wait for a break in the weather (we've been in the double digital negative temperatures with a fair bit of snow), and see if I can put the tank back on and fire it all up.  It's supposed to be 6°C and raining on Monday, so that'll clear it up and maybe give me a chance to test the tank/petcock on the bike.

As it is, the new petcock is leak free on the tank (I just held it up and tipped it over a basin, but no fuel leaked), so that's a result!  The problems with this non-runner when I got it had me focusing on the fuel system to the exclusion of all else.  I'm hoping that after a carb rebuild and the various other fuel system nick nacks I've sorted, that's all that's needed, but you never know.

With any luck I'll actually get to ride the thing up and down the driveway later this week and find out what else it might need.  If it's sorted, I can focus on winter maintenance on the Tiger and do the LED turn signals I've got for both bikes next.  Come spring time I'll ride it over to my local motorbike shop, Mostly Ironheads, and have them do a safety on it and then get it sorted for the road.

'98 Fireblade Winter Project: Wiring & Petcocks

With the carbs sorted I'm chasing down anything else that could have caused the fuel leak into the engine on the Fireblade.  Yesterday I had the petcock out of the gas tank again and tested it over a catch basin.  Fuel flows fine when it's on, but it continues to drip when it's supposed to be closed, so a new petcock is in order.  Fortunately they seem to be a regularly replaced maintenance item because you can buy them on Amazon for not much money.

The neutral light wasn't working, so I got some LED replacements - they're super bright.  The wiring to the neutral sensor was stripped down by the drive sprocket, so I cleaned it up, reattached it and taped it up.  Voila, working neutral light again.

There were also a set of wires coming out of the drive sprocket housing that look like they go to a speed sensor which were resting on the exhaust pipe and had melted.  These too got sorted and re-wrapped.  I'm also going to fasten that loom so that it can't touch the exhaust again.

There are still lots of little details to sort, but the Honda is coming together nicely.  I'll aim to have it safetied in the spring and then run it for a few months and see if having a second bike in the garage is worth hanging on to, or it might just be sold on to fund the next project.  In the meantime, I'm looking forward to running my first true sport bike.