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Project 39 Passes Its Final Exams

7/18/2023

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On Sunday I completed the final test ride for Project 39, my 1993 VFR750. The first run was 57 miles, which I use for initial checks and to bed in the brakes and scuff the new Bridgestones. Back in the shop I addressed any issues found, then on this longer ride I run the bike through all its paces. I'm aiming for about 100 miles and so I make a backroad loop to my favorite coffee shop, 2894 On Main, located in the heart of East Troy, WI which lays claim as the former home to Buell Motorcycles.
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But on this day it served as a half-way butt-break for coffee and a huge molasses cookie at a picnic table in the too-quaint town square across the street. As usual, I leave the large side fairings off the bike to allow detailed checks of the mechanicals. The ride totaled 97 miles and I couldn't find a single nit to pick — the engine ran smooth and strong, the temp gauge sat at about 1/3, the ride was controlled and tracked perfectly, the suspension upgrades front & rear working well together. The new Delkevic muffler brought out the V4 music without being at all brash and the bike revved cleanly. A gas mileage check brought 47 MPG with moderate throttle inputs.

I'm still awaiting my newly upholstered OEM seat so I was using the tattered Corbin which came with the bike. I aways carry a tail pack with some tools and repair bits but, as usual, didn't need them. When I chose the chain & sprockets for this bike I went with a 1-tooth larger front sprocket, lowering the highway revs by about 400 RPM for a slightly calmer riding experience, and probably aiding the fuel mileage a bit. With six gears to choose from I've never found the 750s lacking in acceleration even with lowered gearing. I also tested the GPS mounting which is hardwired and quickly detaches for transferring to my other bikes. Also added are a set of heated grips, but those didn't come into play on this perfect summer day. I've also mounted a taller "touring" windscreen on this bike which still looks good and seems to work just fine keeping a little more wind force off my torso. On order are a set of Knight Design lowered pegs which should keep my old(er) joints happier along with the Helibars up front. Can you tell I'm leaning towards the "touring" half of sport touring?

With its final exams complete I can now do a final fastener check, any needed cleaning and mount the rest of the fairings. I'll also be applying my own decals to this project, purposely not clearcoated so it can revert to the original look, if desired (I have a full set of stock decals). In September I'll be taking the bike on a 4-day ride in the southern Blue Ridge where it should prove the perfect mount for all the fantastic twisties the mountains are famous for. I've ridden the area several times but, inexplicably, never on an Interceptor, so am really looking forward to this trip.

East Troy is a pleasant midwest village located at the mid-point between Milwaukee and Beloit along the I-43 corridor. It has about 6000 residents, a small railroad museum, Gus's Drive-in, LD's BBQ and is also near the Alpine Valley resort and music venue. It's a place where American flags fly and kids can still play safely while Harleys and hot rods rumble slowly through the town square where local musical performances are a regular summer attraction. There's even some good roads nearby…and good coffee.
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Mid-season Reminder

7/15/2023

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Today marks the "weather" mid-summer point here in the upper half of the globe, and the middle of winter temps Down Under, I suppose. While many parts of the U.S. are suffering under oppressive heat and threatening weather, here in the upper midwest we're enjoying mostly moderate conditions with little rain — some perfect riding days. On Thursday I got Project 39 out for its first test ride which proved that the '93 will be a great bike once I address the few niggles that arose. So here's a reminder to not let the season slip away. Get out and ride, even if just for a short evening jaunt.
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Project 41 Comes To Life

7/11/2023

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Yesterday Project 41, a 1987 VFR700 F2, awoke after several years of slumber. Following an oil change, valve adjustment, compression check and a freshly rebuilt set of carburetors mounted, the button was pressed and "Old' Blue" fired instantly. After a brief warmup the sync gauge was connected and the screws were turned till the carbs were happily playing together.

This bike is showing 32,000 miles and was hatched May of 1987 from the Marysville, Ohio assembly plant in Candy Wave Blue & silver. There's no shortage of cosmetic issues here, but my first step is always to confirm mechanical viability, and it appears that this one has passed that test. Here's a short start-up video….
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Underseat Projects

7/9/2023

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As I complete the finishing details on Project 39, my 1993 VFR750, there's several tasks to finalize before covering the area under the tail fairing and seat. In this photo we can see some of these jobs completed — there's an aftermarket Mosfet regulator/rectifier installed, battery tender leads attached, relocated starter solenoid, chopped passenger peg bracket and new brake fluid reservoir.
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Mosfet R/R — Replacing your OEM R/R is a reliability upgrade. Mine came from RoadsterCycle and I chose the "Super Mosfet Kit" which is complete, over-engineered and a tight fit; about $180. The flimsy OEM wiring is replaced with more substantial gauge and requires soldering or crimping to the three stator wires. The new R/R has its own positive and negative leads which connect directly to the battery. As supplied, the battery leads are unnecessarily long which I shortened for neater underseat routing, but not really necessary. The OEM positive/negative leads are no longer used so I simply repurposed them for battery tender leads which cross over and exit out the bottom of the left-side fairing.

​In the photos below you can how I routed the battery leads so that I could still use the battery cover. The negative wire simply runs under the cover and out the rear while the positive sneaks out a slot cut into the front of the cover. That red box is the built-in circuit breaker — I put a tie-wrap around the flip-open lid as an extra bit of security. There's two exposed lugs under the cover which would cause electrical chaos if accidentally grounded. You can see the large black wire behind the battery which takes these leads to the R/R.

Also in this photo is my new battery hold-down strap. Mine was missing in action and NLA from Honda, and in my search for a replacement most of what I found were cheap, generic, too-long straps which reviewers reported to last only a few months. I finally found these in a 2-pack on Amazon which fit perfectly.

The second photo shows where I needed to grind the upper portions of the R/R fins for fairing clearance. The upper mounting screw is simply a large sheet metal screw while the lower is the original threaded mounting stud. The Mosfet is larger than the OEM R/R and a tight fit, but it does fit if angled just right.
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Starter Solenoid — My replacement shock absorber, a Honda 929 item, has a large reservoir chamber on top, which was pushing against the starter solenoid and not allowing the battery to drop into place. The solenoid is attached to the battery box via a metal bracket spot-welded in place. Looking at the wiring, I realized that the solenoid could be relocated to the right side of the battery box if I could move its bracket.

(Below) With the battery box on the workbench, I drilled out the welds, pried off the bracket, found its new location and pop riveted it in place. Reinstalled in the frame, the solenoid fits happily in its new location.
(click on an image to enlarge)

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Footpeg surgery — I'm eliminating both passenger footpeg assemblies on this project, but I still need the fairing mounting points, so I performed some major bracket surgery, saving only the needed piece. You can see the finished bracket in the lead photo.

​I do have spare brackets in the event a future owner would like to return the bike to stock. ​

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The left side passenger bracket was likewise modified — cut, smoothed and polished. I left the seat/helmet lock and handle in place, although my lock was MIA and I haven't been able to locate one, so the lock is simply by-passed for now.


(Below) Here's the finished right side with the original rubber shield in place, ready to button up.

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Replacement Carb "Fuel Joints"

7/8/2023

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I've just completed a 2d-gen carb rebuild for a client who supplied aftermarket replacement fuel and vent tubes for me to install. These are available here from eBay seller vinscoot who hand-makes them for several bike models, including our VFRs. They're TIG welded and sell for $85 complete with nitrile o-rings. Nitrile is not quite to the spec of VITON (which I supply) but is suitable for and commonly used in fuel systems.

The tubes installed just as the original plastic items with a nice, snug feel. We're fortunate to have guys like vinscoot helping to keep our bikes on the road — thanks!
(click on an image to enlarge)
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Gorilla Fix

7/7/2023

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I'm just about to attempt to fire up Project 41, a 1987 VFR700 which hasn't run in at least nine years. When I do, I always mount the full airbox and filter. This bike came to me with the airbox lid drilled with holes which seems to be a common misguided go-fast modification. Until I locate a replacement my hillbilly fix is to tear strips of tape to seal those holes. For this I use the strongest tape I've ever come across, Gorilla brand black tape. I think this stuff would stay in place through the apocalypse and so might actually be a practical long-term fix, so will work fine for this purpose.
While I was messing with this, I happened to notice that the snorkel on another 2d-gen airbox I have on hand looked a little different. Sure enough, this '87 is a shorter version of the same design, even showing the same numbers cast into the plastic. I have no idea why…maybe to give a little extra clearance from the frame for cleaner airflow?
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In The Course Of My Day...

7/4/2023

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Today is Independence Day in America, with family and food on the agenda, often too much of one or both.

But yesterday I found myself working on various items, including mounting a set of freshly repainted wheels onto Project 39, a 1993 VFR750. I had these professionally repainted in the base color of the pearl white (with no pearl). I refinished the rotors myself and installed 90° valve stems, plus a little detail with red added to the cast-in directional arrows. Finally, Bridgestone T32 tires, in OEM sizes, were spooned on. These wheels will be the finishing touch to this project.

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I also received the replacement mirrors for the '93. These are EMGO direct reproductions for the 2000-01 VFR800 but bolt right up to the '93. I like them as replacements for the 3d- and 4th-gen bikes with their bulky, and often worn out, rubber-covered stems. I think they give a lighter, sleeker look.

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I also made some disassembly progress on Project 41, a 1987 VFR700, including removing the brake calipers and master cylinders. I find all manner of surprises when I open master reservoirs, from pristinely clean to what was found in this bike's clutch reservoir. Looks like peanut brittle but without the taste. Also note the mold and corrosion growing around the sealing edge. Makes me wonder what the rest of the clutch hydraulics look like.

Happy 4th of July to all Americans, and let's all take a moment to appreciate how fortunate we are to be living in free and independent societies, wherever that may be.
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The VFR As The Do-It-All Motorcycle

7/2/2023

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This tongue-in-cheek image recently appeared on ADVrider.com's VFR thread. It clearly places the Honda VFR as the most versatile motorcycle of all time. I especially like the little cooler strategically placed above the headlight and the second giant tankbag on the canoe.
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'96 VFR750 For Sale In New Mexico

6/29/2023

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PictureClick on image for the eBay link
What: 1996 VFR750F
Why: Low miles, complete, original
Where: Albuquerque, NM
Price: Auction/$5499 OBO

The 4th-gen VFR is the furthest Honda took the carburetor-ed V4 development, adapting fuel injection and many more changes for the 5th-gen 1998. That's not an indictment of carbs — they have a satisfying visceral, analog feel for many of us. But, fuel injection was the future and that technology will never retreat.

Today's example has a few things going for it, showing only 15,240 miles with a few rare period extras and very original condition with the exception of the muffler and a strange rear fender/tail light modification. Extras include a full set of very rare color-matched RKA soft saddle bags/tail pack, Renntec luggage rack, Vance & Hines slip-on, passenger seat cowl, grab bars and tool kit. The seller knows the bike's ownership history, having bought it from his friend, the original owner. Also available via a Craigslist ad, offered at $5499 or reasonable offer. Ebay auction ends July 4th.

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VFR800 Bodywork For Sale

6/26/2023

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Found on my local Craigslist, here's a full set of 6th-gen VFR800 tank and body plastics listed for $500 in Deerfield, IL, a north suburb of Chicago. They're obviously from an Anniversary Edition, but will fit any 6th-gen. Our seller states that they were previously painted black (apparently with the decals left in place?) and show "no cracks or signs of repair." If that's true and the tank is rust-free inside, then the asking price seems fair — I would figure about $100 additional to ship this collection so that would need to be considered. Want to try a custom look for your 800? Need to replace your damaged bodywork? Here ya go.
(click on image for the C-list ad)
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Click on image for the C-list ad
Here's a few ideas….
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