Refurbishing my '99 5th Gen

Discussion in '5th Generation 1998-2001' started by GreginDenver, Jan 13, 2017.

  1. GreginDenver

    GreginDenver New Member

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    Thanks guys, I really do appreciate your compliments.

    Yeah, I've always had what I think of as "OCD on demand", a mental game that I can turn on and off when necessary (maybe it's my superpower). Or maybe it's just part of any Introvert-Nerd-Techie personality type.

    This ability has served me well throughout my life, I wouldn't be where I am today without it.
     
    Last edited: Jan 26, 2017
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  2. duccmann

    duccmann Member

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    OCD on command--- funny
    Keep up the GREAT work


    Sent from my iPhone using Tapatalk
     
  3. RVFR

    RVFR Member

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    ^ what he said..
     
  4. GreginDenver

    GreginDenver New Member

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    Today was Valve Clearance and Adjustment on the rear head...

    I didn't have to do anything to the Exhaust Valves, they were all still within specification.

    I was very concerned about getting through this process without errors or forgetting something, so I took it slow. On the way I got a few photos of my work.

    [​IMG]

    [​IMG]

    I took pictures of the parts in their original positions before I disassembled them. That allowed me to reference the pictures to make sure I reassembled everything in the correct orientation...

    [​IMG]

    [​IMG]

    I marked each camshaft gear in two places (paranoid, I know)...

    exhaust side:
    [​IMG]

    intake side:
    [​IMG]

    Here are the results:

    Here's Cylinder #1 (with new shims installed). Cylinder #1 original clearance check was 0.14mm on the left side and 0.135mm on the right side and the original shims were: 180 on the left side and 182 on the right side.
    [​IMG]

    Here's Cylinder #3 (with new shims installed). Cylinder #3 original clearance check was 0.14mm on the left side and 0.14mm on the right side and the original shims were: 180 on the left side and 182 on the right side. (Yeah, both cylinders had the same shims in the same places)
    [​IMG]

    My results are very satisfying, I decided to adjust the Intake Valves toward the high side of the specification range allowance of 0.16mm + or - 0.03 (0.13mm to 0.19mm), I was aiming for 0.18mm.

    After reassembly and rotating the engine about 5 or 6 times I rechecked them with the feeler gauges and found that all four are now perfectly set to 0.18mm!

    New O-rings, new bolts, moly assembly lube on the camshaft journals, buckets and lobes, careful attention to torque values. Camshaft timing was very easy to re-establish (I love these gear driven camshafts).

    Can't wait to hear this engine run again.
     
    Last edited: Jan 27, 2017
  5. tyarosevich

    tyarosevich New Member

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    If you're not too concerned with wet performance and you want good tire life, the Pirelli Angel GTs are amazing. They have a nice aggressive profile and turn in very fast, with excellent grip on dry pavement (still decent on wet). Their only drawback is that they have a braided steel belt and if you ever do a patch you have to be sure to rasp the living sh&t out oof the puncture or the belt will shear the plug in half.
     
  6. Lint

    Lint Member

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    I've heard great things about the Angels, I've just never run them. For the money, I think the T30 EVOs are a great buy. Since you don't live buy me, I used www.motosport.com for a price comparison.

    Angel GT $315 a set
    T30 EVOS $246 a set
     
  7. RVFR

    RVFR Member

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    Gee Lint don't be such a tight wad, JK. Good deals are hard to turn down, but those Angels are pretty darn good tire
     
  8. GreginDenver

    GreginDenver New Member

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    Finished up the Valve Clearance Check and Adjustment...

    Worked on the front cylinder head check/adjustment yesterday. The intake valves in the front cylinder head were in worse condition than those in the rear cylinder head because 3 of them were out of specification. Both of the intake valves in Cylinder #2 were sitting at 0.12mm and one of Cylinder #4's intake valves was also at 0.12mm

    After doing the standard Shim Valve math to determine the sizes of replacement shims I would need to correct the valve clearances I was lucky to find that 3 of the shims I'd just removed from the rear cylinder head would work perfectly in the front cylinder head.

    Here's cylinder #2. Both intake valves in this cylinder measured to the same clearance and so they both got the same size of replacement shim.
    [​IMG]

    Here's cylinder #4. One intake valve was out of specification and the other was sitting at 0.16mm which is right in the middle of the acceptable specification range, but because I had a shim (from the rear cylinder head) that was 0.02mm smaller I decided to install it in this valve to bring the clearance up from 0.16mm to 0.18mm (I should point out that all the Honda shims that are marked "182" test out at a actual size of 1.827mm on my micrometer, so this shim is more of a 183 than a true 182).
    [​IMG]

    The final results for my front cylinder head valve adjustment are: Cylinder #2 left valve = 0.17mm and right valve = 0.17mm (remember that the Honda "182" shims actually measure out to 1.827). Cylinder #4 left valve = 0.17mm and right valve = 0.18mm (probably closer to a 0.185 actually).
     
  9. Lint

    Lint Member

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    :)

    So I've heard! I know that there is someone over in VFRD that lives by Tail of the Dragon that is supposed to go through tires on an almost daily basis due to riding those roads so hard, he has used them and had good things to say about them. I've thought about trying them, but my local tire pump gets the T30s at a volume discount, so...
     
  10. Terry Smith

    Terry Smith Member

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    I have an Angel GT on the front end of my ST1100. The tyre is lasting really well under the heavy weight of the ST, and sticks tenaciously (no chicken strips here). I'm pretty sure the tyre is a dual compound and as a result would give great mileage if straight up and down is your thing. I would like to try a T30 Evo next though.
     
  11. mello dude

    mello dude Administrator

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    I can soooo identify with this ---- "OCD on demand" ---- That's great!!
     
  12. VFR4Lee

    VFR4Lee Member

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    Is there anything you did not take apart? :eek:
     
  13. RVFR

    RVFR Member

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    It's this right here 6th gen owners that make the 5th gen what it is. Gears, and add a bit of whine and you have sweet music
     
  14. CandyRedRC46

    CandyRedRC46 Member

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    Remove the front silencer gears to make some more music.

    Sent from my Nexus 6 using Tapatalk
     
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  15. Riding a 2000

    Riding a 2000 Member

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    Love it, of course.....
     
  16. GreyVF750F

    GreyVF750F Member

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    You're very methodical on your approach with the pics and writing things down. OCD is good! Don't rebuild/repair without it. It makes things easier and you always have a record of what's done and how. Good job, you're my kind of mechanic.

    Oh yea go with the T30 EVO's you will not be disappointed. For the best price on them and any tire is here: http://www.americanmototire.com/catalog/index.php?cPath=33_82_1154
     
  17. tyarosevich

    tyarosevich New Member

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    Hey I got a lot of respect for someone that makes-do with a tight budget and puts in their own time to make a great machine to enjoy. I'm sure the Battlax tires are great.

    Love seeing these super thorough cleanup threads! Keep it up!
     
  18. GreginDenver

    GreginDenver New Member

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    Spent the day refurbishing the brakes... I hate working on brakes.

    Like everything else on this '99 the brakes were a mess. If there's a good side it was that the brake pads and the disks are in very good condition with lots of life left in them.

    On the bad side, the brake fluid in the Master Cylinders was obviously 18 years old (okay, maybe the prior owner added a bit here and there over the years but probably not a full fluid flush/replacement). After the incredible filth and crud I found while rebuilding the Front Brake Master Cylinder and the Clutch Master Cylinder, I certainly wasn't looking forward to working on the brake calipers and the clutch slave cylinder.

    But it had to be done, so here we go...

    Popping the pistons out of the brakes:
    [​IMG]

    [​IMG]

    [​IMG]

    And this is what I found:
    [​IMG]

    [​IMG]

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    [​IMG]

    Here's what the Clutch Slave Cylinder looked like:
    [​IMG]

    [​IMG]

    [​IMG]

    It took a lot of scrubbing but eventually I had three clean, rebuilt brake calipers (new piston seal sets installed) and a clean, rebuilt clutch slave cylinder:
    [​IMG]

    [​IMG]

    [​IMG]
     
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  19. Riding a 2000

    Riding a 2000 Member

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    Awesome!

    I Have to get to the same jobs you are doing.
    Quick question: Did you use Honda branded parts or go aftermarket?
     
  20. RVFR

    RVFR Member

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    Wow talk about awful and going the distance, this is going to be one clean 5th gen once finished ;)
     
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