As some of you know I picked up this bike a while back. It had sat fore some time and only has 22k on the clock. It came with the alternator and starter in hand and the chain was frozen. I pulled the engine and replaced the chain and it is now back in the frame and sort of running. the first problem is that it fell off the jack as I was putting it back in the frame by my self and broke the left engine side cover which was not entirely repairable with marine tex but I was able to get it running for now to set everything else up. So the first question is: what years will fit other than 87 and 88 and does anyone have one for sale? I should know tomorrow if the wrecker two hours away has one. Next, I have an intake leak on the insulators as Honda calls them. They are the parts between the head and the carbs. I've tried removing the stops on the clamps with little change. The runners from the carbs to the air box seem to have shrunk as I can't to get them to reach far enough to attach to the carbs. Now, I went through this with my Nighthawk but they were pretty hard and the cbr's are not, so I'm kind of stumped on this one. My air box is dammaged as well. Honda wants $55.00 each for them so I'm wondering if K&N's will work. I know they don't on the Nighthawk even with rejetting. If they will work does anyone have a jetting recomendation? I'm running Super Trapp slipons so I can adjust the back pressure with them. Sorry for the long questionere but I could sure use some help from those who have gone through this before.

 

Moved it here to get better response

K&N pod filters are not a good idea unless you have plenty of time for tuning
As for the engine cover and airbox - best bet is e-Bay - maybe UK if you don't find one in the US.
If you want new ones - www.cheapcycleparts.com or www.mrcycles.com
As for the carb rubber boots - a good alternative is good quality radiator hose of the correct diameter.

Hope this helps
Welcome back !

 

Left crankcase cover Ebay

Cheapcycleparts new listing and diag

works for 87 ---->

 

Thanks for the replies, I'm not afraid of rejetting except for the cost but I have that problem somewhat in hand now. The ten thumbed purported Lexus mechanic I bought this bike from scroomed up virtuall everything he touched. One of the insulators. intake runners to me, was on wrong but the carbs to the air box just barely make it but good enough for now. He also thought #1 was on the right so assembled everything backward.The real good news is that I found a fuel pump relay and a side cover for a good price and their on their way.

 

Hey:

Just so you know the fuel pump is not needed and was discontinued on the later models, you can go gravity feed and all will work just fine without the pump and parts left out don't need maintenace or leave you stranded.

If you ever need the carb insulators as mentioned, above use hi quality radiator hose of the correct diameter, this also works with no issues.

The airbox design on this particular Honda is very well done,flows and flows quite well, but K&N pods can be used as mentioned by Shadow, but take time for tuning to get as good as the stock box or better. Start at + 2 sizes mains with stock dual pipes + 3 sizes with after market duals or 4:1 if @ sea level and go from there. A sigma jet kit may work for you or just a main jet change. trial and error is the only good way other than local dyno time for this. http://www.ebay.com/itm/Honda-Hurric...item35b84cb707

They (K&Ns) work fine on the Nighthawks you just have to be good at tuning to get it correct, just like the CBR1KF, it is not a simple and easy 1 main jet change like some other bikes.
Plus many modern tuners are so used to EFI and multiples maps to get it perfect, older carb bikes take more time effort to get better and they do not have the experience or patience to get it done correctly. It is a sign of the modern times.

A good welder should be able to repair/rebuild your cover and may be less than ebay, some times, so don't rule that out either.

Good Luck with your project

Dub

 

Thanks for all the info. I managed to pick up a cover and everything else I needed from ebay. I took it for the first short ride today and it feels and runs well except at idle. I have synced the carbs and still am having a pretty rough idle. The jets are clean so it might be an intake leak or I may have to pull the carbs again and cut the tabs from the low speed adjusters and clean those ports and reset the idlle mixture. I don't have a tach that will detect 50 rpm but I have a feeling that any drop in the rpm will be around 50. As I mentioned before this bike sat for a very long time, so much so that the piston on the cam chain adjuster was stuck and the chain made a heck of a noise. I pulled the adjuster and freed the piston easily and it sounds fine now. I'll keep you posted.