Author Topic: Bringing a Connie back to life  (Read 1303 times)

Offline K_C_M

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Bringing a Connie back to life
« on: October 02, 2017, 11:48:23 am »
Hi Everyone, I have embarked on an ambitious project to bring a Connie back to life (called a GTR100 in the UK).  She is a late 94 model and has not moved for at least 2 years, probably more and stored in an open carpark in the lovely British climate.  Nothing worked and everything was sized.
I have cleaned, drained refilled and serviced all parts as I work through them and I am now trying to start the motor. I charged the battery, changed the plugs, tested the coils (all OK), put fresh fuel in the tank. At first the bike cranked over and sounded like she wanted to go but never quite fired.
I checked the carbs and seemed no fuel was getting to cyls 2 & 3, so I stripped and refitted the carbs, full rebuild. I re charged the battery showing 12.65 volts but now when I press the starter button I get a click from the starter relay and the Jbox but nothing happens! I also noticed that now the indicators don’t work at all (they worked before I removed the carbs). Headlight working, instrument cluster working, brake lights working, horn working, just no starter and no indicators
Any suggestions where to start fault finding?

Offline gPink

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Re: Bringing a Connie back to life
« Reply #1 on: October 02, 2017, 04:06:48 pm »
Welcome to the forum. I'd suggest starting with a new battery.

Offline dboogie2288

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Re: Bringing a Connie back to life
« Reply #2 on: October 03, 2017, 08:17:40 am »
Tap the Jbox, do you get any lights or starter? Might need a rebuild.

Offline K_C_M

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Re: Bringing a Connie back to life
« Reply #3 on: October 03, 2017, 10:39:00 am »
OK. The battery is not new but holds a charge and I have tried the battery from my brothers Honda Blackbird, but the same result.  The Jbox was a refurbished one from Lawrence at Buck Sport Touring who seems to have a good reputation for rebuilding these things.
I was wondering if there might be a problem with the earth, so that a full circuit might not be getting made to the starter, but why would everything else work except the indicators?
Kevin.

Offline gPink

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Re: Bringing a Connie back to life
« Reply #4 on: October 03, 2017, 02:45:28 pm »
12.65 is not really o k

Offline K_C_M

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Re: Bringing a Connie back to life
« Reply #5 on: October 09, 2017, 07:38:14 am »
You'er right, it was not OK. She was dead, but now she lives. Connie is alive! She’s alive!
I re-charged the battery and tried once more, but with the same result (funny that!), so I unhooked the battery and started dismantling: first the cam chain tensioner (manual after market type), then the alternator and then the starter motor.  When taking off the alternator the manual says ‘remove the mounting bolts’ and shows a photo with arrows pointing to 2 bolts.  There is in fact a 3rd bolt hidden away deep under the alternator that requires a long 6mm Allen key.  That done, getting the starter motor out requires that you have an angled 10mm ring spanner, but don’t undo the bolt all the way or the spanner snags against the oil filler cap just as the bolt comes loose but not out of it hole.  The result is that you have to manipulate the bolt with your fingers in a spot you cannot see to turn the bolt back in just far enough to release the spanner!
The starter seemed to have been jammed, but once it was off I applied the battery 12volts to it with jump leads and after the first attempt it sprang into life.  So, I lubed everything up, checked the ‘O’ rings were all OK and put all the bits back together.
Now to try again… I had taken the plugs out of cyls 1 & 4 just to make cranking a little easier and also to check that I was getting a spark. I pressed the starter button and  … it worked!  I had sparks on the plugs for 1 & 4 so I replaced them, re-fitted the tank and tried again.  Connie coughed a few times and obviously wanted to start, but after 2+ years of not breathing she was obviously finding it difficult.  I sprayed a liberal quantity of BRADEX into the airbox and pressed the button again.  This time she coughed and fired.  Billowing smoke at the back end from the bradex but with a bit of choke and a gentle hand on the accelerator and she settled down to an idol at about 1100 RPM.
Now her heart is beating, the next move is to adjust and balance the carbs, rebuild the front and rear suspension, refurb and refit the brakes, flush the cooling system and oil and do a full service on everything.   That’ll keep me busy for a few more days.
Kevin

Offline Hooligan

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Re: Bringing a Connie back to life
« Reply #6 on: October 09, 2017, 07:49:37 am »
Welcome to the forum, and well done on getting her started after a 2yr+ coma.
It is what it is....If not, it must be something else.
08 GTR 1400
06 Honda Twister

Offline K_C_M

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Re: Bringing a Connie back to life
« Reply #7 on: October 26, 2017, 09:08:24 am »
It’s been a few weeks now since the Connie breathed again.  So now the attention has moved to the front end.  I have a donor set of forks with Race tech gold emulators and a new set of OEM brake disks.  The master cyl & calipers are now overhauled and ready to fit and a set of S/S braided brake lines.  Pads will be EBC sintered pads. Oh .. and a fork brace.
That all seems straight forward, but should I change the head race bearings and maybe the front wheel bearings before I put this together? Is there anything else I should do at the same time?
What tyres (front &Back) would be a good combo as I might as well get the tyre changed while the wheel is off

PS.  Does anyone know of a way to retrofit anti-lock brakes, or a complete front end replacement with anti-lock brakes?

Offline kzz1king

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Re: Bringing a Connie back to life
« Reply #8 on: October 26, 2017, 09:17:19 am »
For sure I would do the front wheel bearings. How many miles on the head stock bearings?
Wayne
2010 CONCOURS
1974 Z-1

Offline K_C_M

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Re: Bringing a Connie back to life
« Reply #9 on: October 26, 2017, 11:04:20 am »
The bike has 98000 miles on the clock. Previous owner has done some work including swapping the engine (no idea of the millage on the motor!). The front wheel is off Ebay and she has stood still in an open carpark for over 2 years.
I think that I should probably get the bearing and replace them before I put the front end on.

Offline Hooligan

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Re: Bringing a Connie back to life
« Reply #10 on: October 26, 2017, 10:52:42 pm »
If it was me, I would most definitely do the wheel bearings, as well as the neck bearings.

Good luck with the rest of the build, and please post some pics when she is completed?
It is what it is....If not, it must be something else.
08 GTR 1400
06 Honda Twister

Offline K_C_M

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Re: Bringing a Connie back to life
« Reply #11 on: November 15, 2017, 10:17:19 am »
I decided to get the bearings done and sort out the brakes. I had all the bearings delivered for the steering head, the front and back wheels and the swinging arm. I also got new stainless steel hoses, master cyl and caliper service kits for the brakes. So I was set up to get things going!
Getting the front end to pieces was easy and then got everything cleaned up and started on the front wheel bearings. A day later, I was still hammering away at the 1st bearing and there was no movement whatsoever. The next day I spoke to a local bike garage and he said ‘No problem, I’ll have it done in 2 minutes’. I thought he was a bit ambitious, but took the wheel in anyway. Sure enough, 2 minutes later the bearings are laying on the floor! I got him to drift the new bearings in and the job was done.  5 minutes of his time vs 1 day of my time cursing and swearing. Money well spent.
Next job was the steering head bearings. I started with the easy stuff, the top roller bearings came out when I dismantles the steering yoke and a little persuasion was required to take the bottom bearings off the steering stem using a bearing puller. However the outer bearings left in the frame were a different matter.  Another whole day of bashing away.  After about an hours work the bottom bearing was drifted out with an angled flat bar but the top bearing has such a small lip it was impossible to get any purchase on it at all so I obtained a piece of 1½ inch solid steel bar. Within a few minutes and 6 solid whacks of my hammer the top bearing was out. I drifted the new bearings in using the old bearings. I got the Yoke back on the bike and that was another job done.
The fork legs were drained and dismantled at the beginning of the week and fully dismantled. I rebuilt them with sonic springs and cartridge emulators from race tech, using W15 oil. Assembled the forks and fitted the front wheel. Joy!.  She’s starting to look like a bike again.
Front Brakes Next...

Offline tweeter55

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Re: Bringing a Connie back to life
« Reply #12 on: November 15, 2017, 02:38:18 pm »
 :popcorn: Good read.
Do not try to live forever on this earth. You will not succeed.