PW80 is Rolling!

A fully functional stable!

After banging my head against a non-starting PW80 for the better part of two weeks I went back to basic troubleshooting.

The one thing I changed prior to it dying entirely was the spark plug.  The only NGK I could find was a BPR6HS, the bike is supposed to take a BP6HS.  The difference is a resistor which prevents feedback to electronic equipment in the system (important if you've got a machine that uses computers and other finicky components - the PW80 is nothing like that complicated).

I'd read that the resistor doesn't matter, but after swapping back to the old plug the bike fired up immediately.  I've got to look further into resistor effects on simple two stroke machines like the PW80, but the troubleshooting still stands: when you change something and it suddenly stops working, change it back even if you think it's supposed to be an improvement!

I'm going to regap and try the newer plug again, but if it kills it again I'll have to accept that the PW80 doesn't like (and doesn't need) a plug with a resistor in it.

After it was up and running we had a throttle lesson, walking next to the bike while my son got a feel for rolling on the throttle gently.  I then tore around in circles on it - it's a zippy little machine!

Sanding Concours

One small heater does the job now that I have
garage door insulation installed.

A good couple of hours were spent in the garage today getting the scratches and dents out of various Concours panels.  The previous owner had used some kind of plastic filler to put back together the lower right fairing after it had been dropped.  With some hand sanding today I've gotten it close enough to prime and prep for a round of painting.  If it isn't perfect it'll be much closer than it was.

I'm trying to find the Tremclad metallic red similar to the blue I used on the Ninja, but I'm having trouble finding it.  Home Depot seems to have dried up on it.  That paint with the gloss clear coat comes very close to looking like it came from a body shop.

I'll keep looking.

The small heater did a good job of heating up the room to 18°C (it was -8°C outside).  The garage door blanket is doing its job nicely.

Got the rear fairing piece around the seat off and prepped for painting.

Everything sanded and cleaned, ready for some primer.

Connie stripped down to the tank.

Old Motorbike Electrics

Turns out the Concours didn't need a new bulb, it just needed some more electrical connection cleaning.  After replacing the bulb that wasn't blown I finally took off the fairing only to discover that, like all the other electrical gremlins, it was a matter of dirty connectors.

After cleaning up the wiring harness, suddenly all the lights work again.  I posted what happened on the COG discussions and got this pearl:

COG wisdom

As usually happens in a case like this, you immediately see the good advice repeated. Only a couple of nights later I was reading Performance Bike Magazine. They do a bit each month on what to look for in finding an older model sport bike, in this case the thirteen year old Honda VTR1000 SP2. In the article they suggest that cleaning and protecting all electrical contacts on a bike that old is a good winter-time activity.  If it's true for well cared for sports bikes half as old, it's even truer for my field-found Connie.

As WillyP states above, bikes aren't built to keep out the elements, even the most covered bike is virtually naked compared to a car. Even in the case of a well cared for, covered sports bike, cleaning the electrical contacts is a worthwhile off-season ritual. In the case of a field-found Concours, it's where I should have started in the first place.  A breakdown and electrical cleaning is my go-to next time around.

As a project bike the Concours continues to teach lessons even as it becomes more and more roadworthy.

Chain and no Agony

Follow up to Chain & Agony and How to Size and Replace a Motorcycle Chain...

The whole process of breaking the chain and installing it took about half an hour this time around.  The o-ring chain I got was easy to break using the tool I picked up, and installing the new master link on the chain took only moments.  The three in one DRC Chain Tool I got (chain breaker, outer plate presser, rivet presser) was easy to use and looks good doing it.  It might be my favourite tool at the moment.

The chain-breaking tool comes with two sizes of /privet pushing bit.  The blue bit was for 500 sized chains (the Ninja's is
a 520).  You back off the big bolt and install the push pin, then use the smaller outer bolt to push the pin into the rivet on the chain. The tool automatically centres the rivet, so you're true all the way through.

The new chain was a 120 link chain, the Ninja takes 114 links, so that's 6 links off the end.  The hole in the
top is where the chain pin falls out once you've pushed it through.

Close-up of the blue chain bit .  There is a pin inside it that the outer bolt pushes through, pushing the rivet
right out of the chain.  Once the pin falls out the chain falls apart.  You end up with a clean break and two
inner chain links ready to be re-attached on the bike with a master link.

Six links of the 120 link chain removed.  One pin is pushed right out, the other was pushed
out far enough to dismantle the chain.

I installed the master link on the sprocket - it keeps everything lined up and made installation easy.  After
pressing on the side plate (gently, checking that it's in line with the other links and the chain has play in it),
the only tricky bit was installing the retaining clip, it took a few tries.  When you get it though you know for
sure because it makes a very satisfying click.

With the chain back on and lubricated, everything is tight.  The change to how the bike feels is subtle
but very satisfying.  The engine feels much more firmly connected to the back wheel now.  No sags and tight
spots like on the old chain.

I got this mighty DRC Pro chain
tool at Royal Distributing in
Guelph.

Now that I've got a handle on this and the right tools for the job, chains don't worry me any more.  This process also emphasized how surgical bike mechanics are.  I started off doing heavy equipment repair as a millwright and then did a couple of years in automotive.  Compared to that kind of work, motorcycle mechanics feel more like surgery than butchery.  Patience and a careful hand are more important than brute force.

Now more than ever I'm looking for an old bike to dismantle and rebuild to get an inside feel for how motorbikes go together.

10k

I looked at the odometer today as I pulled into the parking lot after my forth straight day of commuting and realized my '07 Ninja has finally hit the 10k mile mark.  The commute got her there, it's about 70kms each way with the first two thirds a country ride through the Niagara Escarpment, then an 11 km blast down the 401 before it slows down going into the GTA, then another couple of kms in Milton.  It's a nice ride.  Less so when it's pouring buckets of rain out of the sky, as it has for the last two days, but those were memorable rides too, even if uncomfortable, and a bit treacherous.

This weekend the Ninja gets round two of its spa treatment, a coolant flush and change and a cleanup after all that wet riding.

I was at Two Wheel Motorsport the other day getting oil filter and gaskets and the older guy behind the counter was talking about how it isn't about how you do the miles, but about getting the miles in.  I'm beginning to see his point.  Wheelies and high speed corners are all well and good, but there is something to be said about being the saddle and putting miles behind you while you're out in the world.

It's Sunday afternoon and I'm taking a movie break with the family before coming back and finishing putting the bike back together again.  I got the coolant flush done (though what came out was about as perfect as I've ever seen used coolant), cleaned the engine while I had the fairings off, and stripped the black off the tank.  The goal is to get the bike roadworthy for another week of commuting to Milton... that'll be another 700kms behind me.