1986 Aspencade Resurrection

[3KidsinAustin]

Last of the parts out of the ultrasonic cleaner. I'll have the cleanest secondary air system around!

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[Fred Camper]

Wow, looks like a surgery room.

[3KidsinAustin]

Reassembled the four carbs bodies and attached them to the plenum today. Still need to set the floats before buttoning them all back up and reinstalling.

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Of note, I am hopeful the air vent tubes are correctly aligned. I am disappointed that the Halasz book does not clearly illustrate which end the tubes point. Neither does the factory manual, which seems odd. I think someone has been into these carbs before, so the best I could do is put together the same way they came out. If anyone sees an error, please let me know.

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[3KidsinAustin]

One key part I found in the rebuild book from Randakk's is the brief section referencing using a water-pik to check all the passages. I've always used compressed air and never would have thought of the water-pik idea on my own. It really came in handy, as during the final inspection before joining with the #2 carb body, I tested the unique vacuum port on the #4. I think this feeds the ignition module, but don't have my notes to confirm. I checked it with my vacuum gauge and it was not allowing air to pass, so clearly blocked despite all the time in the buzz box. Enter our unused water-pik! I purchased it for my daughter while she had braces and I don't think it every got used much. Plus, she has had her braces off for about six months, so I figure I'm good to go for using it to clear a carb passage!

It took a bit of pressure building, which liquid does much better than air, and then a high pressure jet shot out of the middle of the carb body with lots of sediment settling quickly to the bottom. Success!

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Just providing a method to clear that vacuum passage so I didn't have to pull the carbs again was worth the price of the book. However, if anyone from Randakk's actually reads this post, PLEASE insert a diagram showing the air vent pipe alignment.

[robin1731]

Closest thing is a diagram on page 145 in the Honda repair manual.

If you look on the cover of your carb rebuild book you can see it says "Distributed" by Randakk's.
The author is Howard Halasz.

[3KidsinAustin]

Big day today! Carbs were reassembled a few days ago, but I finally got a chance to leak test them on the bench earlier this afternoon. I'd sourced a huge syringe to try and fill the rear shocks (fail), but it worked perfectly as a container hooked into the gas line from the fuel pump. All the float bowls filled then stopped, with no leaks! Let it sit for several minutes checking it all around until I was satisfied. First carb rebuild in a long time, nice when it ends with a success.

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With the float bowls filled with fuel, the only thing left to do was to slide the carb assembly back into the bike and test it out. So, on went the top cover (reference post #33 for THAT little issue) and new o-rings sealed up the intake tubes to the head.

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Then, engaged the choke lever and hit the starter button. After just a few seconds of cranking, the old gal fired up! Idled smoothly for about a minute before I shut it down as no cooling system installed yet. (I did need to twist the throttle a couple of times, just to make sure the throttle blades were moving smoothly... )

Video link below, about 20 seconds of it idling immediately after it started up for the first time.
https://youtube.com/shorts/UREcIn2xWxM[/youtube]

Next up is checking the charging system as the alternator might be toast. I took it into the local O'Reilly's for testing and it came back as a FAIL. However, I'm not overly confident that the counter staff know what they are doing on older parts. If no exciter wire, then no charging. I am not overly optimistic, but that will be the next step. Following a good charging system will be the installation of the radiator, then things start to get buttoned up. Exciting!

[Fred Camper]

Lots of solid progress for sure. Good luck finding an easy fix for the charging system.

[3KidsinAustin]

Lots of solid progress for sure. Good luck finding an easy fix for the charging system.

My guess is the "easy fix" will be buying a new alternator! Charging system took a back seat today as I decided to try and fill my rear shocks with oil. I had drained them by leaving them upside down in a pan for a couple weeks. They were mostly out of the way, although I managed to knock them over a couple of times in the interim.

My first attempt yesterday was to use my big syringe and push it tight into the air fitting to let allow gravity to feed it into the tube. My fitting wasn't 100% air tight as after about 10 minutes I noticed some fluid starting to exit where the syringe entered the junction block. Time for Plan B.

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Having a press sure comes in handy from time to time. I compressed the shock, watched the bubbles come out, then released the pressure from the press to allow the shock to expand. I discovered after a couple of routines that it takes awhile for the ATF to get sucked into the shock, so have to let it sit for a few minutes between cycles. Long process, but it seems to be working.

Typing this out between cycles on the first shock. It has sucked up about 200cc (WAG) so will continue until the bubbles stop.

[Fred Camper]

Wow, laborious process. Makes me think I would rather buy new ones.

[ritalz]

I was able to fill mine with a syringe. Still it was a slow process. Measured out some fluid into a jar, filled the syringe, pumped it in a little at a time until the jar was empty. Press idea looks like it works but I don't have one.

[3KidsinAustin]

Wow, laborious process. Makes me think I would rather buy new ones.

Not too bad, once I figured the cycles out. Probably 10 compressions per shock, maybe 30 minutes total for each one. Usually working on other things while I wait for the fluid to get sucked up. Now I'm just petting the dog between cycles. We are both happier that way!

[3KidsinAustin]

I was able to fill mine with a syringe. Still it was a slow process. Measured out some fluid into a jar, filled the syringe, pumped it in a little at a time until the jar was empty. Press idea looks like it works but I don't have one.

I bought is used probably 6-7 years ago for a car project, think it was $100. It sits and gathers dust 99.95% of the time, but sure comes in handy for pressing bearings in/out, reinstalling brake pistons, and now filling shocks.

After about an hour of cycling the shocks, they are done! I dressed them up with a set of repo boots from eBay as the originals had rotted away. Will set them up on a shelf until the rear end goes back together.

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I'll be glad to get the oil catch pan off the floor. It's been there catching oil from the shocks for a month or so. Been emptied once, just the slow dregs left. I've only tripped over it a half dozen times or so!

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[ritalz]

At one time I was considering a pipe bender which could double as a press. I don't have a garage here so it would probably be stored at my sons house. Never could convince him that it was a good idea. Plus the fact that he has one at work that he uses. One more thing I would do is to put in some air and submerse the whole works to check for leaks.

[3KidsinAustin]

One more thing I would do is to put in some air and submerse the whole works to check for leaks.

That was a good suggestion. Unfortunately, I forgot there were no Schrader valves in my rear suspension system, presumably because it is controlled by the on board air compressor. Gave it one pump and fluid immediately began back flowing into the pumps air tube. Oops.

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Looks like I'll get to do a bit more fluid injection tomorrow.

[3KidsinAustin]

Didn't have much time in the garage this afternoon as spent time cleaning up my ATF mess and refilling the shock that puked out last night when I added some air to it. However, took a flyer and decided to see if the alternator that was diagnosed as FAILED by O'Reillys tech actually was. Much to my pleasant surprise, it charges up perfectly!

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An extra treat was that the bike started totally effortlessly. Engaged the choke, pressed the start button for a couple of seconds and it roared to life. Settled into a nice, smooth idle and kept at it when I disengaged the choke. Happy Days!

Cooling system will go in tomorrow, then I'll get some longer warm up periods to start synchronizing the carbs and getting it dialed in. Probably find a few surprises as well.