My project - Honda Rebel Forum
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post #1 of 32 Old 05-24-2018, 01:58 PM Thread Starter
 
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My project

Since I purchased the Rebel this is the first weekend I have been able to work on it. I put gas in it would not start. So I ended up having to take the carb apart and cleaned it. I dont know how the guy rode it to my house for delivery as the jets were completely plugged and had a black sandy gel coating covering the entire inside of the carburetor.


I got her put back together and it started had great throttle response. Shut it down when it got later in the day I was going to ride it around the yard and it wont start again. I didn't put a filter on and the petcock screen is missing so I am going to take it apart and clean it again. The manual enrichment valve should be here today as well I purchased a few inline fuel filters.



Since I know it will run I have ordered a few things. New headlight, Brake Master Cylinder, Brake Pads and Shoes, new exhaust donuts, fork seal kit, manual choke valve, Johnny pag hand controls, and a air cleaner. So I have a lot of things to put on it. I still need to get a new clutch handle but im not in a hurry as the one is still functional with a new bolt just loose.


So that is were i am at so far. The wife is complaining about all the money I am spending on such a cheap bike. So next time I am home from work in 3-4 weeks I plan on giving it a oil change, and checking/adjusting the valve clearances as well as getting all the new parts installed. I still need to clean up the wiring I hate butt connectors and having to ohms test every wire to find the other end since somebody chopped it up and added nothing but black wires to it.



So I have a few questions. What is the best way to remove dents from a gas tank ? should I just use bondo ? Also can I buy a new wiring harness ? I would like to buy one instead of buying all the wire and plugs and building on from scratch I can do it, I just don't want to. Once I get the parts put on in a few weeks I will update this thread with some new pictures.


I plan on getting my motorcycle endorsement once the bike will pass inspection. I rode for years with out one but I figure im not a teenager on a 1000cc sport bike anymore. The Rebel is not known for its speed and acceleration.


Link to photo album of bike said images were to large to upload here.
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post #2 of 32 Old 05-24-2018, 02:39 PM
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that's a huge bike rescue you got going

new wiring harness - no

you can find a used wiring harness on ebay

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post #3 of 32 Old 05-24-2018, 03:54 PM
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Sounds like there may be crud in the tank and that is what's fouling the carb. In-line fuel filters only cost a few bucks, and it sounds like you need one. http://www.hondarebelforum.com/f39/h...ter-13278.html

And if you want to clean the tank: http://www.hondarebelforum.com/f39/t...ning-7168.html

Dents don't bother me, but I understand wanting to fix them. Probably the cheapest method is a new tank. The Chinese made, larger volume, tanks are notorious for leaks and I recommend lining them with Caswell epoxy before ever putting fuel in them. https://www.caswellplating.com/epoxy...-to-5-gal.html

If you go the bondo route, after painting, a two part, fuel resistant, clear coat should be applied.

Keepin' all the left over parts. Gonna use 'em to build another bike!

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post #4 of 32 Old 05-25-2018, 01:30 PM
 
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Just a guess but you got a Gen-1 for the love and fun of the restoration, else you would have spent less money on a good running Gen-2 (as the wife said, lol)
From the imgur posts you linked to I couldn't see any bad dents...bondo and paint will cover/hide them, for bad ones a body shop can spot-weld pull points and pop out dents and grind them back off so's you'd never know after the repaint. If the inside of the tank is roached you'd probably be better off with a replacement, much less cost and hassle.

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"The bravest thing for me to do is admit when I am wrong" - unknown
HRF Answer #1 You should take the MSF Rider Course
HRF Answer #2 You need to clean your carburetor
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post #5 of 32 Old 05-25-2018, 01:55 PM Thread Starter
 
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Just a guess but you got a Gen-1 for the love and fun of the restoration, else you would have spent less money on a good running Gen-2 (as the wife said, lol)
From the imgur posts you linked to I couldn't see any bad dents...bondo and paint will cover/hide them, for bad ones a body shop can spot-weld pull points and pop out dents and grind them back off so's you'd never know after the repaint. If the inside of the tank is roached you'd probably be better off with a replacement, much less cost and hassle.



I actually got it for $150 so the price was unbeatable. I think I can get a solid running bike for a total of $750. I also like projects every daily driver that I own has an Antique tag and the rebel is only 2 years away from that and is my newest vehicle My wife hates how i buy crap then spend money fixing it she thinks i just need to buy something that's new.



The dents are not terrible but since im going to get it to be a daily driver and then strip it down this winter and get the stupid paint job off of it. You cant tell but they sprayed the ceiling popcorn crap on it then painted black over it I just don't understand some people. As for the tank its nice and shiny on the the inside I have filled and drained it a few times. I think the cause was the fuel line as it was brittle and flaking i just really wanted to hear it run. With the new fuel line so far no problems.



Also I have a few sticks of lead was thinking of teaching one of the kids how to lead fill old dents as it seem to be a dying art. But the wife screamed about lead poisoning are kids, so I will probably bondo fill as the dents are creased.
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post #6 of 32 Old 05-25-2018, 04:34 PM
 
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Originally Posted by abnormalspring View Post



Also I have a few sticks of lead was thinking of teaching one of the kids how to lead fill old dents as it seem to be a dying art. But the wife screamed about lead poisoning are kids, so I will probably bondo fill as the dents are creased.
Actually the reason it's a dying art, aside from the excessive weight, is probably that the guys that did a lot of it have all died of lead poisoning..
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post #7 of 32 Old 05-29-2018, 02:47 PM
 
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I remember doing jute and lead seals on household cast iron sewage lines, PVC glue is SO much easier

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"The bravest thing for me to do is admit when I am wrong" - unknown
HRF Answer #1 You should take the MSF Rider Course
HRF Answer #2 You need to clean your carburetor
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post #8 of 32 Old 05-30-2018, 08:33 AM
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Welcome to forum



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post #9 of 32 Old 06-09-2018, 03:08 PM Thread Starter
 
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I just ordered a new fender for the bike and the Johnny Pag hand controls arrived. Once I get home I am going to be able to put it all back together and go for a ride. I still need to get a seat as it feels like I am sitting on the bars under the seat.



What seats have you guys used that came with good comfort ? Would I be better off just taking the seats apart and getting some 6 inch closed cell foam and redoing them or do new seats really offer that much more comfort? I also saw that the stock throttle cable wont fit the Johnny Pag is there a specific one I need to get to fit ? will any Johnny Pag cable fit the forward controls ?
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post #10 of 32 Old 06-23-2018, 04:35 PM Thread Starter
 
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UPDATE


I have got a lot done this week. Got head light hooked up and working along with the left Johnny Pag control. Ran new wires for the rear turn signals and wired in a new flasher relay. It works with out adding diodes as well as long as you have over 4w and it can handle 41 watts. You can also adjust how fast or slow the turn signal blinks. I also got the front fender in and a new master cylinder installed its nice to have front brakes.



Here are some photos of the progress I have made. https://imgur.com/a/ecttQtL


So I found more problems with the bike after I was able to take it for a ride. The previous owner used a pry bar to get the gas cap off once he lost the keys. So now I have to order a new tank. The clutch also slips in 2nd and 3rd gear if I try to accelerate to fast. The chain adjusted all the way to the back has 2 inches of movement and the rear sprocket is work pretty bad. So I am also assuming the front is worn as well.



So hoping next month I can get new clutch plates and chain and sprockets along with a fuel tank. I am thinking about going 15-30 on the gear ratio was wondering if anybody could give me some feed back on doing so. Such as long term damage or problems that it may cause ? I will probably go to 30 in the rear as people seem to really enjoy the 14-30 ratio.



So its looking like I will be investing another $300 into the bike plus paint once its mechanically sound. I cant complain though $150 for the bike and around $350 in parts and its almost done. So I cant complain about $650-$700 bike.



As always appreciate the feedback.
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