Rainy Day Carburators

A cold, rainy Saturday had me break down the carburetor on the Yamaha XS1100.  A Triumph Spitfire and Mercury LN7 owned as a teen made me pretty handy with carburetors.  In addition to multiple rebuilds I also got handy at jury rigging manual chokes thanks to the utterly crap Ford Escort carb set up.

The beautiful Mikuni unit on the Yamaha looks like a piece of industrial art in comparison to the pedestrian Triumph and Ford carbs, unfortunately it's seized.  After breaking down the top end I soaked it and freed up the seized throttle body.

The next to-do with the Yamaha is to clean up the gas tank and then reassemble the fuel system.  The engine isn't seized and spins easily, so I think I'll have an easy time firing it up for the first time in years (knock on wood).

Here are some pics of Mikuni's Yamaha masterpiece:

The throttle cable wasn't playing nice even after taking apart the handle bar - so into the carb I go...

The Yamaha XS1100 engine block with the carbs off - it got the Warhol treatment....

Like everything else so far, the internals look to be in good shape on the old (35 year old!) Yamaha

Cleaning up the fasteners using the caps from each carb to keep things organized.

XS1100 is in for surgery

Not many riding days left as the weather turns up here in Canada

Midnight Thoughts

What we have here is a Yamaha XS1100 'Midnight Special'.  It looks like it needs some love and is for sale for $500 along with some extra parts.  The flash from the phone makes this '70s bike look pretty disco!

The XS1100 is a late '70s/early '80s 'super' bike.  From what I've read it's Yamaha's Vincent Black Shadow.  You're spoiled for choice as far as customization goes with the XS1100.  It's a big, air cooled engine with the old fashioned dual rear shocks.  It begs to be café racered a bit.

As a tear down/rebuild, this makes a pretty good basis for a winter project.  It would be my first air cooled bike, as well as my first tear down/rebuild.

The Clymer manual is readily available (I'm finding Haynes manuals lacking in covering many motorcycles).  This could be a winter sanity thing.

My First Honda: Fireblade!

I've had a pretty diverse group of R&R  (repair & recover) motorcycles to date.  My first R&R bike was the '94 Kawasaki Concours ZG1000 back in 2014.  Purchased for eight hundred bucks and cut out of long grass to get it out of the field it was in, the Concours got sorted over the winter and put back on the road where it took us to Indianapolis and went on to over twenty thousand kilometres of mileage before I sold it on for what I purchased it for this past summer.

The Concours became my regular riding bike so I sold on the Ninja.  Eventually a KLX250 off road bike came into the garage, but didn't last long as I struggled to find ways to use it in Ontario: land of no fun.  That led to a too-quick purchase of a Yamaha XS1100 from an entirely dodgy kid that led me into the headaches of sorting ownership.  That experience has made me more cautious in buying used bikes.  The belief is that all motorcyclists are salt of the earth types, but that isn't my experience; shifty would be a better description.

So far I've been able to make money on my R&R projects, Shed and Buried style, but I don't make it easy on myself.  Both the Concours and the XS1100 were big, four carburetor bikes with spaghetti loads of vacuum tubes and complex wiring.  I've taken my time looking for the next project and tried to look for something simple, air cooled and single cylinder, but bikes like that don't come up often.  As the summer fades and winter approaches, it was time to commit to a new R&R project.

This 1997 Honda CBR900RR Fireblade came up on Facebook buy and sell.  I've found the local nature of Facebook's marketplace offers up interesting opportunities that you don't find on the hardened semi-pro sellers of Kijiji and Autotrader, where you are much more likely to find shady characters who sell a lot of crap.  This twenty-two year old non-running Honda got me curious enough to contact the seller in Alliston.

It turns out the bike had gotten tangled in a divorce and was then sidelined.  It was eventually used to settle debts between the estranged couple, but now it belonged to a non-rider with no mechanical experience who just wanted it gone.  Her new partner was trying to sell it for her, but with it not running he wasn't getting any calls.  A late nineties CBR in safetied, running condition was going for about $4000, he was asking $1200 for this one as is.

We exchanged a number of emails, both of us cautious as we'd both met idiots from online sales (it turns out the internet is actually full of idiots).  As we got to know each other I asked increasingly direct questions - was is repainted to hide crash damage? (no, the former owner didn't like the stickered stock look)  - why is it in this state?  (where I got the bad karma backstory this bike was unfortunately wrapped up in).  The last problem to solve was how to get it here.

During our give and take the seller offered me the bike for $1200 instead of $1300, and then said he could trailer it down to my place for $100, so I got it at asking price with a $100 delivery charge.  The bike showed up and we had a good chat and ended up being given a milk crate full of pears from his parent's farm too.  Bonus Honda pears - good deal.  This low mileage, non-runner seemed like a steal upon first look.  The paint's a bit rough, but for a 20+ year old low mileage bike, she cleaned up a treat.

I was told the bike was a non-runner due to the carbs.  As I got into the bike mechanically I figured I'd look at the fuel system as a whole rather than only looking solely at the carb since I didn't know how long it had been sitting.  I'm glad I did.  The fuel tank had a worrying amount of rust in it.  I talked to people on the Practical Sportsbike Magazine Facebook group (one of my go-to bike magazines and a great place to talk to DIY types) and got suggestions around various acid etching and chemical routes.

I went out to Canadian Tire aiming to get some industrial grade hydrochloric acid but found Metal Rescue Rust Remover, a water based environmentally friendly solution that neutralizes rust and prevents more from forming.  It also helps the tank retain its structural integrity whereas acid eats holes in it.  My first go at a motorcycle tank cleaning (I've been lucky so far and not had to deal with it) went well.  I left the chemical in the tank for about six hours before recovering it back into the bottle (it can be reused).  With the tank sorted it was time to look at the rest.

The vacuum operated fuel pump in the bottom of the tank was clogged and a mess, but it too cleaned up nicely.  With the big end of the fuel system sorted out, I turned to the carbs.

Compared to the buried in the frame carbs on the Concours and XS1100, the Honda's are a joy to access.  Having seen the mess that was the rest of the fuel system, I figured the carbs were crammed full of guck, and they were.  The only other issues seemed to be more about mechanical cack-handedness than wear.

Once on the bench I've been able to isolate some obvious problems.  I found a spring laying under the carbs on the engine case.  If you're fixing a carb it generally helps to use all the parts.  I also found that one of the choke pins were broken, so the choke was only working on three of the four carbs, and the choke cable itself wasn't attached correctly, so the choke was only moving about 2/3rds of the distance it should.  These are all things that would prevent the bike from starting properly.

Yesterday I took the float bowls off and had a look at the bottom end of the carbs.  The ethanol in modern fuel is not a good mix with older fuel systems, like carburetors.  Not only can it eat away at the rubber and gaskets in older systems not designed for it, but it can also leave varnish, and worst of all, it's a water absorber, so it can lead to corrosion in older, gravity fed systems.  If there was ever evidence of modern ethanol based fuels making a mess of a carburetor, it was here in this old Fireblade, where every carb bowl was worse off than the one before it.

Thanks to some judicious use of carb-cleaner, they cleaned up nicely, but does ethanol ever do a job on mechanical fuel delivery systems!  Fortunately, if I stick with super unleaded from most stations in Canada, it means I'm not running any in this old bike from now on.

I run super in my bikes anyway because they're very fuel efficient anyway so it doesn't cost much and, at least on the Tiger, the power commander means I can maximize power out of it.  For the Honda or any other carb fueled bike, you should be running super just to stay away from the ethanol.

Today I'm going to pull the tops of the carbs and have a look at the state of things (I'm hoping better than below) and finish cleaning them.  I'm also going to see if I can fix that broken choke pin on carb 4 or else I'm going to have to track down the part.  Bikebandit has it for $50US, but no one else seems to have one available.

There are other bits and pieces in this poorly looked after carb that are suspect.  Rather than use boot clamps to attach the carb to the engine, the muppet who owned it before me appears to have put some kind of rubber sealant on them and attempted to 'glue' them to the block.  This is stupid in all sorts of ways.  Bits of this rubber seal would deteriorate in the gasoline rich air-fuel mix and get sucked into the engine, and there is no mechanical connection ensuring the carbs are tight and leak free to the engine.  For a system that runs on vacuum, this is a disaster.

The boots have cleaned up nicely, so I also need to source some ring clamps for them.  The Honda specific ones are hard to find, but I'm hoping I can find some aircraft grade ones that are an engineering match and easier to source.  Oetiker Clamps, ironically based in Alliston where the Honda came from, do some nice, high quality options that I should be able to fit.

So much of mechanics come back to common sense.  The guy who owned this before seems to have had a startling lack of it.  I'm hoping for $1200+$500 in parts I can get this Honda humming and ride it for a year before seeing if I can double my money on it (unless we bond).  Safetied bikes of similar vintage with twice the mileage are going for four grand.  Even with all the work done so far, the bike hasn't cost me a penny in parts and I may be within spitting distance of sorting out this abused Fireblade.

Follow up:

Tops of the carbs were fiddly - the plungers are a pain to reseat properly, but I worked through them and all the top ends have been cleaned, though they were all in good shape as befitting a low mileage bike like this.  The nastiness was all in the float bowls.

I gotta say, I'm enjoying Honda engineering.  Kawasaki has a real heavy industry feel to it by comparison, though my Kawi experience is mainly on a big sport tourer and this Honda is built for one thing only... getting down the road quickly.  But this bike has an engineering elegance to it that makes it a pleasure to work on.

With the cackhanded way this bike has been worked on, there are a number of fiddly bits missing or broken. I was sourcing ring clamps (x8), a choke plunger and other odds and ends and found the price quickly creeping up.  I reached out to local bike breaking yards and only heard back from NCK in Woodstock, ON, who seem organized and on their game.  They have a donor carb in used, rust free (stored inside) condition for $250CAD.  That's within fifty bucks of where I was with buying bits and pieces and means I'd have a lot of spares I could always sell on after.  I'm going the donor carb route this week.

Oh, and Oetiker clamps got back to me and apologized for not having what I needed because (of course) the Honda's clamps are a special size and would require special manufacturing.  My quest for carb hose clamps continues.

NOTES:

One of the tricky bits of working on old bikes is getting the documentation you need to work on them accurately.  The internet is a gold mine for this.  If you're working on a late '90s Honda CBR900RR Fireblade, you'll find this handy:

1996/7 Honda CBR900RR Owner's Manual:  https://mototribu.com/constructeur/honda/1996/1000cbr/doc/revuetechnique_900rr.pdf

It has lots of good technical graphics in addition to all the specs you need.

***

I was also able to source the Haynes Manual for this bike from Fortnine on sale for only $35.  Most other places were over $40US, so finding that on sale was a good first step in this project.

At the moment I've got emails out to The Bike Yard in Caledon and Oetiker Clamps in Alliston.  With any luck I can source the bits I need and have this Honda purring even before the snow starts to fly, then I can spend the winter sorting out the other fluids and maintenance before it hits the road in the spring.

Yamaha XS1100: The Midnight Saga

Buddy Jeff gave me a hand getting the XS1100 home the other day; he's an enabler.

Getting it on the trailer was a bit tricky as the front calipers were seized.  A couple of whacks with a rubber hammer loosened them up enough to get the wheel rolling.  It took three of us to get it up onto the trailer - it's heavy (600lbs), had mostly flat tires and was still grabbing the brakes, but we finally got the job done.  We ended up settling on $400 as is, which gives me a working budget of about $1500 to get the bike back on the road.  It think it's doable.  The only other one like it for sale at the moment is asking $3300.  After looking at the bike again critically before agreeing to buy it, it's in surprisingly good shape for what it has been through.

Once home we had a victory beer after wrestling it off the trailer.  A bit later I had a go at it with a garden hose and some S100 cleaner.  The ride over had blown away most of the cobwebs, but the rest of the bike is quite astonishingly clean considering it has been sitting outside.  The S100 also has a corrosion inhibitor, but I also soaked the bike in wd40 in preparation of trying to remove any fastener on the thing.

Trying to muscle the 600+ pound bike into the garage earned my my first Yama-scar, but I eventually got it nestled in there.

In other news, here's something to know about bike ownership in Ontario (and probably elsewhere): if you're buying a bike off someone who bought it and never transferred ownership to themselves, you need to make sure you've still got chain of ownership intact.  This means either a piece of writing from the legal owner saying that the bike was sold to the intermediary or a signed ownership.  The kid I bought the bike off had neither (can't find them).  He's looking.  More updates to follow.

It's getting crowded in there - once the season ends
the garage will only need to hold the Concours &
the Yamaha, everything else will winter in the shed.

In the meantime, the history of this old bike is long and storied.  I'm the fourteenth (!) owner (almost).  It's a 1980, not a '78 as the kid selling it thought it was.  In the early '80s it went through three owners before finding itself at Norwich Collision Service in South West Ontario in the spring of '82.  The crash owner had owned it since Christmas and had probably been on the road for a few weeks in the spring before spilling it.  Idiots buying bikes too powerful for their experience level isn't a new thing then.  He got the bike back from repair and immediately sold it.

After the n00b crash and the repairs it got picked up by a guy who owned it for six years.  He then sold it on to a series of owners through the '90s and zeroes, the longest being eight years by a guy in Halton.  The last legal owner was a guy from Stoney Creek in 2009.  

Whoever said the Ontario vehicle history was boring or a waste of money?  This one reads like a Jane Austen novel!

I'll update the ownership situation as I hear more, hopefully it'll be resolved by the end of this weekend.  I'll hold off on working on the bike until I know I can own it, that seems prudent.

Sense of Satisfaction!

After all the Maker talk this week at a conference I attended, I was keen to spend some quality time in the garage working on the 35 year old XS1100 basket case.  It's easier to walk the walk than talk the talk when it comes to Making.  Unlike the education approach infused with collaboration for your own good, I did it the way I always do: alone in a garage.  It's wonderfully cathartic to get something broken working again, and meditative when I don't have to explain everything I'm doing.

How do you get a 35 year old motorcycle left outside for several years unattended working again?  Very carefully!

The front brakes were seized, the throttle body was seized, the rear brake is still seized, as are other things I haven't found yet.  Motorcycles aren't like cars, when they're left in the world they don't have a shell protecting the mechanicals from the weather.  Restoring a car tends to be more mechanically salvageable as a result.

Yamaha XS1100 Mikuni Carburetor by timking17 on Sketchfab

I ended up having to take the end carburetor off the rack of four Mikunis that line the back of the Yamaha engine.  It was the most carboned up and filthy one, and the grit had seized the throttle body rod.  A complete dismantle, cleaning and reinstall has the carb working again (before this you couldn't move the throttle body without great effort and a nasty creaking sound...

It took a couple of hours to break it down, find the problem and rebuild it.

It was pretty before, but the Mikunis are even prettier now that they work!

XS1100: Steps Toward Resuscitation

Snow last night, the XS got some mechanical
attention today as a result.

After looking over some internet advice (sic) on how to start a long dormant motorcycle engine (and ignoring never ending discussions on it), I got the XS1100 to the point where it would crank over (with spark plugs removed).  The plugs look brand new, but sooty.  Cleaning them up and regapping should be all that's needed.  It's nice to know it isn't seized, the electrics aren't pooched and the starter motor sounded solid.

I also have the airbox off and the carbs cleaned (though they look pretty clean before I did them).

The gas tank is a rusty mess, it was left outside and empty for a length of time.  I'm thinking about doing some instructables chemistry on it, just to try it.  Failing that, I think I'm going to try Evapo-Rust.

Here's what it looked like today:

Makes you wonder how many motorcycle tires don't get worn out before they need a change.

With the airbox removed, the wall-o-carbs is easy to get at.

Carb internals look to be in good shape.  Only the throttle cable is suspect.

The air box has cleaned up nicely

Evolution of Motorcycle Ownership and a Triumphant Return

Back in August of 2014 I wanted to take a more active role in my motorcycle maintenance.  At that point I'd been riding for just over a year on my first bike, a very dependable 2007 Kawasaki Ninja 650r.  I learned a lot on that bike, but it was a turn-key experience, the bike needed very little in the way of maintenance.   

The Ninja went from flat black to metallic blue and orange.  It was the last bike I rode that people commented on (I'd often get a thumbs up or have someone stop and chat in a parking lot about how nice the bike looked, which was satisfying as I'd been instrumental in restoring it from angry-young-man flat black).  The Ninja was, without a doubt, a good introduction to motorcycling, and was the king of the roost for my first two seasons.

As a first bike, the Ninja led the way both on the road and at the top of the blog.

I wanted my next bike to be one that ran because of my mechanical skills rather than one that didn't need them.  I found a 1994 Kawasaki Concours sitting in some long grass about twenty minutes away.  I quickly discovered that sense of satisfaction I was looking for.  The Concours was an eager patient who rewarded a winter of mechanical work with a rock solid five thousand miles of riding the next summer.

The Concours has offered some memorable rides, especially looping Georgian Bay and riding on the Indianapolis Motor Speedway.  For a bike that looked like it was being permanently parked with only 25k on it, suddenly it was back in the game, going places other bikes only dream of.

That busy season of long rides took its toll on the Concours though.  It isn't a spring chicken and after having spent the better part of two years parked before I got to it many of the soft parts on the bike were getting brittle.  I parked the Concours early and began winter maintenance knowing that the bearings and brakes both needed attention only to miss out on a late season warm spell at the end of November and into December.  I took that one on the nose figuring that's what happens when you ride an old bike as your daily rider.

The header on this blog for the past eighteen months, but running a twenty-two year old bike as your daily rider
makes for frustrations.  Time to be less sentimental and more rational in how I manage my stable.

That summer we were touring on the Concours I picked up a KLX250 to experience off road riding, but doubling insurance costs for a bike that I only managed to get out on a handful of times didn't feel very efficient.  That I struggled to keep up with traffic on it didn't support the way I like to ride.  Motorcycles are open and unprotected, but they are also agile and powerful enough to get out of a tight squeeze - except when they aren't.  The Concours was always there and the preferred ride, owning the road when I was on it.  When I went out with my co-rider he also loved the big red Connie, not so much the rock hard, under-powered KLX (he only ever rode on it once for less than five minutes).

Over the winter I put some money into the Concours, doing up the rims and getting new tires.  With the rims off I also did the bearings and brakes.  As everything came back together again, suddenly the carburetors weren't cooperating.  They're since being rebuilt and the bike should be back together again this weekend, but instead of always being there, suddenly the Concours wasn't.  As winter receded I could hear other bikes growling down the road, but I was grounded (again), even though I was paying insurance on two machines and longing to get back out on the road after an always too long Canadian winter.

The KLX was the first to go.  I'd never really bonded with it and, even though I always figured I'd run this blog with my most recent bike in the graphic at the top, the KLX never made it there; it never felt like the main focus of my motorcycling.  In the same week my son's never-ridden PW-80 got sold, and suddenly I had some money aside.

Ready to go with a new header, but it never took.

As days of potential riding keep ticking by and the carburetor work drags on, the Concours started to feel like an expensive anchor rather than the wings of freedom.  I had a long talk with my wife about it.  She asked why I don't unload it and get something dependable.  Keep the old XS1100 for that sense of mechanical satisfaction, but have a bike that's ready to ride.  I think sentiment was paralyzing me.  Hearing a rational point of view with some perspective really helped.

Many moons ago,
a pre-digital Triumph

With cash in an envelope I began looking around.  Before Easter we weathered an ice storm, but only two days later it was suddenly in the teens Celsius and bikes could be heard thundering down the road.  Meanwhile I was waiting for yet more parts for the Concours.  Online I was looking at sensible all purpose bikes that would fit a big guy.  Vstroms and Versys (Versi?) came and went, but they felt like a generic (they are quite common) compromise, I wasn't excited about buying one.

Since I started riding I've been on Triumph Canada's email list even though I've never come close to owning one (out of my league price-wise, no one else I know had one, no local dealer... pick your reason).  As a misguided teenager I purchased an utterly useless Triumph Spitfire, and in spite of that misery I've always had a soft spot for the brand (your adolescent brain makes your teenage experiences sparkle with emotion even when you're older, that's why we all still listen to the music from our teens).

A Tiger?  On Kijiji?  Must have
escaped from a zoo!

While trawling around on Kijiji looking at hordes of generic, look-a-like adventure bikes I came across an actual Tiger.  It was (as are all Triumphs I've mooned over) too expensive for me, but that Lucifer Orange (!) paint haunted me.

Another rare warm afternoon wafted by with the sounds of motorcycles on the road so I thought, what the hell, and emailed the owner.  He'd been sitting on the bike for the better part of two months with no calls.  He was going down to the Triumph dealer on Thursday to trade it in on a new Street Triple and knew he was going to get caned by them on the trade in price.  He emailed me back and said if I had three quarters of what he'd been asking, he'd rather sell it to me than give the dealer the satisfaction.  Suddenly this fantastic looking machine was plausible.

The garage is 100% more functional than it was last week,
100% more glamorous too!

A trip up to Ontario's West Coast and I got to meet a nice young man who was a recent UK immigrant and a nuclear operator at the Bruce Plant.  The bike was as advertised (well looked after, second owner, some minor cosmetic imperfections), and suddenly I owned a freaking 2003 Triumph Tiger 955i!

Most used bikes offer up some surprises when you first get them, and they usually aren't nice surprises.  The Ninja arrived with wonky handlebars the previous owner told me nothing about.  The XS1100 arrived with no valid ownership, something the previous owner failed to mention during the sale.  So far the Tiger has had nice surprises.  It arrived with a Triumph branded tank bag specific to the bike.  Oh, by the way, the previous owner said, the first owner put a Powercommander on it, and then he handed me the USB cable and software for it.  It had also been safetied in October, less than two hundred kilometres ago (paperwork included), so while I didn't buy it safetied, it shouldn't be difficult to do.  The bike has fifty thousand kilometres on it, but I then discovered that the first owner did two extended trips to Calgary and back (10k+ kms each time) - so even though it's got some miles on it, many of them are from long trips that produce minimal engine wear.  After giving it a clean the bike has no wonky bits under the seats or anywhere else.  I cannot wait to get riding it.

So, here I am at the beginning of a new era with my first European bike.  I've finally picked up a Triumph from the other side of the family tree (the bike and automobile manufacturing components of Triumph split in 1936), and I've got a bike I'm emotionally engaged with.  It might even be love!  Like the BMW I rented in Victoria, the controls seem to fit my hands and feet without feeling cramped and the riding position is wonderfully neutral.  When I'm in the saddle my feet are flat on the ground - just. Best of all, I don't look like a circus bear on a tricycle on it.


With the Concours officially decommissioned and awaiting (what are hopefully) the last parts it needs before being road worthy again, it's time to update the blog header:

What's next?  The Concours will be sold with only a modicum of sentiment, the Tiger will be safetied and on the road (it cost $90 a year more than the Concours to insure), and I'll enjoy having an operational, trustworthy machine made in the same place I was with lots of life left in it.  The fact that it was getting me thumbs up and one guy stopping to say what a nice bike it was when it was on the trailer on the way home doesn't hurt either.  Riding a tiger has a certain magic to it.

When I want to turn a wrench I'll work on the XS, getting it rolling again for the first time in years.  I'll get the ownership sorted on it (affidavits are required!) and eventually sell it without losing a penny, and then I'll go looking for my next project bike.  Maybe a scrambler Versys, maybe an old Interceptor, maybe something I haven't thought of yet.

Time for some unbridled Tiger enthusiasm!

Tyger Tyger, burning bright, 
In the forests of the night; 
What immortal hand or eye, 
Could frame thy fearful symmetry?

In what distant deeps or skies. 
Burnt the fire of thine eyes?
On what wings dare he aspire?
What the hand, dare seize the fire?

And what shoulder, & what art,
Could twist the sinews of thy heart?
And when thy heart began to beat,
What dread hand? & what dread feet?

What the hammer? what the chain, 
In what furnace was thy brain?
What the anvil? what dread grasp, 
Dare its deadly terrors clasp! 

When the stars threw down their spears 
And water'd heaven with their tears: 
Did he smile his work to see?
Did he who made the Lamb make thee?

Tyger Tyger burning bright, 
In the forests of the night: 
What immortal hand or eye,
Dare frame thy fearful symmetry?