So Iíd thought Iíd give a bit of an update after all the questions Iíve asked! - Honda Rebel Forum
 
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post #1 of 9 Old 05-12-2018, 06:13 AM Thread Starter
 
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So Iíd thought Iíd give a bit of an update after all the questions Iíve asked!

First of all thanks for the guys answering some of my questions! Not always the answers I wanted to hear but either way it appreciated!

This is my first bike Iíve worked on. Everything is new to me and Iíve had to learn fast!

When I got the bike it was a **** heap! No chain, rust everywhere, engine wasnít running great,


rear shocks held on by a welded washer,



the list was endless! So I started by completely stripping everything other than the engine and electrics and spent a few hours wire brushing everything, Iíve sanded back the major rust on the frame, left the bare meter showing for a ďrougherĒ look.



I then set about cleaning the electrics up, Iíve moved the rectifier/cdi under the tank using the existing mount, cable ties, a clip from Work and foam, (the tank has been lifted so fits with ample clearance!)

The horn has been relocated under the seat. The wiring on these bikes, are hideous. I might in the future strip the whole loom and make one from scratch taking all the i unnecessary **** out. (Pipe up safety police)

Iíve striped and brushed the rattlecanned engine covers and refitted new gaskets. I also fitted a new clutch as it was cheap and I was there anyway. (Really simple job) there were a few snapped cover bolts that Iíve drilled and helicoiled to prevent this issue again, why manufacturers donít helicoil every cast bolt hole i donít know!?

As some may have seen my exhausts were shot! And living in the UK The cheapsest set in England was a staggering £750.

So Iíve made do, stripped all the rust from them, painted them in aircraft grade paint (the stuff I use at work on casings exceeding 1200 degrees) and wrapped them with some 12Ē shortyís on. They have baffles in which gives some backpressure. (Again before the fun police pipe up)




Whatís left to do...

Find some bars I like, the ones on it now look kinda dumb, I want the rise but not the width so some skinny 7-10Ē rise bars are in the cards.

Iíve got to weld some tabs to the swing arm to secure the fender, and figure out how Iím going to mount my seat. I donít want springs.



New headlight has come but I stupidly didnít look in the existing one and see just how much wire is in it, so Iím planning on putting the loom into an old puncture repair tin and strapping it behind the headlight!

New bullet indicators all round will be fitted and Iím currently making a side mount for a liscence plate and tail light to go on! Most of you over the pond have it so easy with your tiny liscenece plates!

Iím gonna be leaving all the metal bare and I will be adding some small details, such as my favourite beer can as a starter motor cover and maybe some more tasteful ďratty-nessĒ

Iím sure thereís more to do and more Iíve done but I will post some better pictures later! For now thatís all!



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post #2 of 9 Old 05-12-2018, 07:24 AM
 
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Originally Posted by Tucker90 View Post
........why manufacturers don’t helicoil every cast bolt hole i don’t know!?....
Believe it or not, many of us have owned bikes for 40-50 years and never stripped a thread due to overtightening.
In wrenching 101 you learn about torquing fasteners into soft metal.
Torque wrenches are used for many delicate tasks ,but are also useful tools for beginners for general fastening jobs to get a feel for how tight is tight enough. 7-8 ft-lbs on header studs or those soft side covers feels like very little torque on the wrench, but that's all it takes.
In wrenching motorcycles, there are many examples of "more is not better".

2004 Rebel 250, 2003 BMW K1200GT (roadburner), 2004 BMW R1200GS(all purpose),
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post #3 of 9 Old 05-12-2018, 07:35 AM Thread Starter
 
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Originally Posted by Duckster View Post
Believe it or not, many of us have owned bikes for 40-50 years and never stripped a thread due to overtightening.
In wrenching 101 you learn about torquing fasteners into soft metal.
Torque wrenches are used for many delicate tasks ,but are also useful tools for beginners for general fastening jobs to get a feel for how tight is tight enough. 7-8 ft-lbs on header studs or those soft side covers feels like very little torque on the wrench, but that's all it takes.
In wrenching motorcycles, there are many examples of "more is not better".


Im an aerospace engineer on civil and military large aircraft engines, every fastener we fit is torqued to a standard load depending on thread size. I work with a variety of metals including magnesium gearbox casings. So I know a fair share about torque tightening and ďfitters feelĒ

I personally never snapped a bolt on the bike by over tightening, just loosening from the PO.

The reason I said this was not everyone has an understanding of threaded fasteners, surely a good fitting practice would be to helicoil cast holes to prevent people from doing this. Every industry Iíve worked in have done this, aerospace, offshore rigs and even down to gas line turbine generators.






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post #4 of 9 Old 05-12-2018, 07:42 AM
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I don't have as many years working on bikes as Duckster, but so far, an impact driver and penetrating fluid have been sufficient to remove every fastener with no problems.

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

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
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post #5 of 9 Old 05-12-2018, 08:00 AM
 
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Originally Posted by Tucker90 View Post
The reason I said this was not everyone has an understanding of threaded fasteners, surely a good fitting practice would be to helicoil cast holes to prevent people from doing this. Every industry I’ve worked in have done this, aerospace, offshore rigs and even down to gas line turbine generators.
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I used to own an airplane, and I'm sure you will agree that if motorcycles were built like airplanes, not too many people could afford to own them. You really can't spend infinite money trying to idiotproof everything. Beginners can learn by watching others and/or using proper tools and manuals. Idiots just have to learn things by experience. Its nature's way.

2004 Rebel 250, 2003 BMW K1200GT (roadburner), 2004 BMW R1200GS(all purpose),
1973 Norton Interstate (in a box in the basement)
1968 Triumph Bonneville
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post #6 of 9 Old 05-12-2018, 08:22 AM Thread Starter
 
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Cool, well thanks guys! This post was more about the bike than standard practices in tightened bolts up...

I used plus gas and a break bar. Donít have an impact driver. Itís never failed me before!

And as for the the airplane I presume it was slightly different to a A380 or a 747. But yes, it is costly but basics like threaded inserts should be common practice. IMO


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post #7 of 9 Old 03-25-2020, 08:25 PM Thread Starter
 
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Thought Iíd finish the thread a year on.

This is what it ended up looking like.




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post #8 of 9 Old 03-26-2020, 05:46 PM
 
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How does it run now?

2016 Honda Rebel 250 - The "Piglet."
AFR sensor equipped and downsized to a 0.105" main jet.
The only changes so far.
Bought on 6/29/19 with 44 miles.
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post #9 of 9 Old 03-26-2020, 07:45 PM Thread Starter
 
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How does it run now?

Absolutely fine!


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