1994 RVF400R Build Project

Discussion in 'Mechanics Garage' started by NorcalBoy, Nov 7, 2018.

  1. Captain 80s

    Captain 80s Member

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    Niiiiiice. Love having a manual switch in parallel.
     
  2. NorcalBoy

    NorcalBoy Member

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    Thanks Cap. It should have already been done during the first go around, but I flaked it off and was going to see if I needed it with the oversize rads. Needless to say, it didn't run long enough to figure that out, rofl. With the new engine displacement, I wasn't even going to give it a second thought. Better to have and not need, than to need and not have.
     
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  3. NorcalBoy

    NorcalBoy Member

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    As most of us are under some form of shelter in place order/recommendation, working from home, or practicing social distancing these days, I have had time to work on a lot of the details and solutions that remained to be crossed off the "to do" list. The most important thing is that I paid off the remaining balance on the engine last Friday and I'm finally out from underneath that pressure and the bleeding has stopped.

    The parts for the digital temp gauges have started arriving.

    Koso billet inline temp sensor adapters

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    The two gauges

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    Had to make a couple small changes to the cad drawing and the cnc progamming for the gauge mount. The way the wires exited the gauges, it was necessary to drill a couple access holes to ensure the wire routing was clean and tidy. Worked with my tutor to get that done yesterday.

    I also got to see how to work with the software to run a simulation that shows exactly how the CNC machine will cut the part. Hadn't done this before, but it was kinda cool to watch the order and path of each step in the cutting, milling and drilling process. By doing this we were able to determine that a modification to the process had to be made to get the piece exactly right. I couldn't figure it out, but my buddy showed me how to trick it into doing what was needed. Learning something new every time I mess with it, just hope I can retain all the program inputs that are needed to run the verification sim in the future. The material stock has arrived and hoping my buddy can fit me in and have the part completed by this Friday.

    The solution for the fan switch arrived yesterday. Bar space is minimal, as the clip ons are pretty short. Looked around on the web for something that would be clean and work in the tight confines. After looking at way too many switch mounts, I settled on the perch switch mount from Highway Dirt Bikes. It replaces the back clamp on the clutch perch with a billet clamp that accepts a 10A on/off switch. I have used their stuff before, they do nice work.

    The switch mount with the switch installed..bonus points to HDB for including Blow Pop's in the shipment.

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    Mounted on the clutch perch

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    I went to McMaster Carr to get all of the high temp wire sheathing and chemical resistant heat shrink to build the harnesses for the fan switch and the gauges. The Koso gauges use 28 AWG wiring for the power circuit, very tiny, so it took some looking to get the connectors and terminal pins to hook them up to the Eastern Beaver 3CS-s fused power solution. Ended up going with Sumitomo MT 090 sealed connectors and I purchased those individually from Eastern Beaver. Dave at Eastern Beaver finished fabricating the harness and shipped everything from Japan yesterday, expect to see it in 5-10 working days.

    I also redid the taillight/rear turn signal wiring and the main harness to get rid of the bullet connectors and old plastic OEM plugs. Switched all those out with Weatherpack and Sumitomo MT 090 sealed fittings. I have now replaced all of the OEM connectors that I could with sealed connectors and eliminated all of the bullet terminals and old unsealed connectors.

    Waiting to hear from the Speedo guys on my faceplate replacement. Might ping them later this week to see where they are at, if I don't hear from them before. I only have one more thing to order and that should be all that I need to finish.

    Started talking to my local Honda folks and I'm trying to work out the details of a deal on a 2019, or 2020, CRF450L. If my economic situation can just hold steady, I might have a new build project coming soon.
     
    Last edited: Mar 31, 2020
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  4. NorcalBoy

    NorcalBoy Member

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    My machinist was able to get the temp gauge material stock on the CNC machine today and got it cut out and bent. My program worked out OK, thanks to Rob's tutoring with the CAD software and the CNC programming.

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    The small hole in front of the bigger mounting hole for the steering stem was one of the things that got added earlier in the week. There will be a small drift pin that fits through this part that engages a matching hole in the triple clamp to keep the mount indexed perfectly straight to the top triple, when the stem nut is torqued down. The stem nut flange will hide the hole and the pin, so it won't be visible. The other two holes are for the wiring and the temp sensor connector to fit through.

    It's a very compact part, with the overall length being 130mm. When the two gauges are attached, there will be a small 16mm space between them and the rest of the "wings" will be hidden.

    Still haven't decided if I'm going to have my polishing guy just polish it, or if I'm going to go to my anodizing folks and have it anodized black to match the top triple clamp.
     
  5. Diving Pete

    Diving Pete Member

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    Anodise it
     
  6. NorcalBoy

    NorcalBoy Member

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    I probably will, just not anytime soon. Got recalled for work...gonna test out my immune system.

    Picked up the mount today after Rob installed the indexing pin and gave it a light polish.

    The base of the mount is machined to fit down inside the top triple, but still clear the top of the triple by about .005"

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    Triple clamp with indexing pin to make it easier to keep everything aligned when torquing the stem nut.

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    The two parts fit together.

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    Mock up of assembled mount

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    Because the mount adds 5mm of thickness where the stem nut used to seat, Rob is machining a new stem that adds back in the 5mm of threads that were lost to the part. The 7075 aluminum rod stock is already at the shop. Rob does a lot of custom adjustable offset steering stem modifications for MotoAmerica guys, so this is easy for him...He says it's easy, no reason to question him, I'll just send money, lol.

    When I have the Tyga stem pressed out of the bottom triple, I'll order up a set of tapered bearings and races to replace the OEM caged rollers. Get it all done in one shot. Still can't decide on the anodizing, but just to eliminate any chance of sun reflection off the part, I'll prolly get it done up in black.
     
    Last edited: Apr 4, 2020
  7. NorcalBoy

    NorcalBoy Member

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    Some pics of some of the engine progress from Mike Norman.

    Cryo treated and bored engine cases with mocked up rod and piston assemblies

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    Crankshaft getting cleaned up to be sent out for balancing and polishing

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    Maybe in a month or so, I'll have a finished engine on it's way back.
     
  8. NorcalBoy

    NorcalBoy Member

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    Received some more pics from Mike

    Crankshaft - Cryo treated, REM superfinished, balanced, super polish on the journals

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    Meticulously cleaned inside and out, access plugs re-installed.

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    In the background, transmission gearsets in plastic - cryo treated, REM superfinished, new bearings

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    Bottom end assembly started

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    More to come as I receive them.
     
  9. NorcalBoy

    NorcalBoy Member

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    Gauge cluster came back today from Dick's Speed-O-Tach.

    I think it is definite improvement and upgraded look. They installed the faceplates, painted the needles orange/red, cleaned all of the condensation wipes from the inside of the glass and reassembled everything. I don't know why, but when I called to pay them, they said NO CHARGE and shipped them back overnight. They wouldn't even let me pay for the shipping. Great guys, if I do say so myself

    Before:

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    After:

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    With the new faceplates and the aluminum foam surround pins they look a lot better, just need to get around to installing the titanium and aluminum hardware, new foam surround, attaching the carbon bezel covers, and installing the LED bulbs to wrap it up.

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    Ordered up an OEM replica carbon fiber chain guard from RSR Moto out of France. Was going to go hugger, but decided to just do the chain guard, as the mounting for the hugger looked a little wonky to me. Hoping it arrives around the end of April.
     
    Last edited: Apr 11, 2020
  10. Captain 80s

    Captain 80s Member

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    Wow. Those look great!
     
  11. squirrelman

    squirrelman Member

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    just wondering why no rear brake line through swingarm mod ? it tidys things up alot, as you know.
     
    Last edited: Apr 11, 2020
  12. NorcalBoy

    NorcalBoy Member

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    Thanks, Cap. I think they are going to be pretty decent when I get them all finished. Getting down to the last few details.
     
  13. NorcalBoy

    NorcalBoy Member

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    Thanks, S-Man. I'm just not a fan of that mod. I like being able to remove the entire brake system, without completely disassembling the whole thing. That, and it sorta reminds me of clear clutch covers, not really my thing. Also not big on drilling holes in structural components.
     
  14. raYzerman

    raYzerman Member

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    Liking the gauges, very nice indeedy!
     
  15. NorcalBoy

    NorcalBoy Member

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    Thanks!
     
  16. OOTV

    OOTV Insider

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    The white gauges look a lot better IMO. Nice!
     
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  17. Alaskan

    Alaskan Member

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    It all looks so great! What a project!
     
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  18. NorcalBoy

    NorcalBoy Member

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    Thanks, Gents. I really appreciate the kind words and positive comments.
     
  19. NorcalBoy

    NorcalBoy Member

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    No update on the RVF....but I got me a new moto today

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    Something to occupy my time until the engine comes back. Gonna need some fine tuning and some ergo adjustments, but I wanna ride it a bit and loosen up the suspension before I start dialing in the sag and settings.
     
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  20. ridervfr

    ridervfr Member

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    Nice firt bike.

    Sent from my LM-G850 using Tapatalk
     
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