1987 Hurricane to 2003 CBR600RR Conversion
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The gold calipers look great and take the look to that of later models. The fender looks good too. Can you squeeze in a bracket from the front mounting boss for the original fender, that runs down to holes in the RR fender?
Today I got the carbs and airbox on, plugged all the vacuum leaks from the half missing California emissions stuff, got the engine wiring done, and got the fuel lines installed and adjusted to fit around the R1 voltage reg I put in. Figured out that I put in 19 hours on the project this weekend. I swear all the mods are making the job take five times as long. As it was getting dark I dropped in a battery and got to hear the starter run. Hoping to fire the engine in the next couple days.
One interesting project was rebuilding the air box intake baffles. The foam on the tubes had turned to dust and I had stripped it off months ago. Found some urethane open cell foam from the leftover packaging for a car radio and cut strips to replace the old stuff. wrapped it around the tubes and held it with rubber bands while I screwed the clamp down on the tubes. I like throaty mufflers, but the intake shriek gets to me, so hopefully this will keep it more mellow.
Just one more observation - I think one of the best things I did for this project was to pick up a fresh set of metric taps and, in particular, dies. Running any original screw that seemed the least bit funky through a die made it go back into the hole nice and easy and torque up smoothly.
Today I got the carbs and airbox on, plugged all the vacuum leaks from the half missing California emissions stuff, got the engine wiring done, and got the fuel lines installed and adjusted to fit around the R1 voltage reg I put in. Figured out that I put in 19 hours on the project this weekend. I swear all the mods are making the job take five times as long. As it was getting dark I dropped in a battery and got to hear the starter run. Hoping to fire the engine in the next couple days.
One interesting project was rebuilding the air box intake baffles. The foam on the tubes had turned to dust and I had stripped it off months ago. Found some urethane open cell foam from the leftover packaging for a car radio and cut strips to replace the old stuff. wrapped it around the tubes and held it with rubber bands while I screwed the clamp down on the tubes. I like throaty mufflers, but the intake shriek gets to me, so hopefully this will keep it more mellow.
Just one more observation - I think one of the best things I did for this project was to pick up a fresh set of metric taps and, in particular, dies. Running any original screw that seemed the least bit funky through a die made it go back into the hole nice and easy and torque up smoothly.
Your getting close to running her buddy. That's a major milestone.
On the fender mount I'm going to do what you said, but may look at seeing if I can find some nice chrome straps to go around the fork tubes for the lower bolt.
There are a couple of things about the fender that are problematic tho. It sits a little higher than what I would like...not terrible but looks just a little off. I can't bring it down much further because the old fender mount lug is in the way and if I go past it nothing to mount to. Also there is a big space on the sides that I need to find some angled plastic to fill the gap. I'm pretty sure I can get it to look pretty good but more work than I thought.
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From: Bainbridge Is., WA
Maybe something like the vinyl coated loop clamps here?
McMaster-Carr
Mcmaster also has them in aluminum but only up to 2" dia. Not sure if that is big enough, as I am not near my bike at the moment.
McMaster-Carr
Mcmaster also has them in aluminum but only up to 2" dia. Not sure if that is big enough, as I am not near my bike at the moment.
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Yes those would work, but thinking a little more "fancy". I might make some up in aluminum and polish them...we'll see how the strap from the old mount point works. Might be just fine with the top bolted to the brake hose clamp points. I will make it out of heavy aluminum. Still working on the fit right now so can't get measurements yet.
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From: Bainbridge Is., WA
Got a little fuel in the tank today and got the bike to idle for a short while. It appears that I will need to pull the carbs and clean them again after sitting for several months even though I drained them. But at least I got to hear the exhaust note at idle, and it was sweet. Made for a major injection of inspiration right as it was beginning to wear off.
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That's awesome! Love that first start...very special point.
I rebuilt my carbs over the winter. All new parts. Jetted for the Vance and Hines pipe...bench balanced. Will need to be vacuum balanced once running, but should run okay right away. I'm good with engines and especially carbs. Have tuned a lot of bikes, atv's and other toys over the years.
I rebuilt my carbs over the winter. All new parts. Jetted for the Vance and Hines pipe...bench balanced. Will need to be vacuum balanced once running, but should run okay right away. I'm good with engines and especially carbs. Have tuned a lot of bikes, atv's and other toys over the years.
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From: Bainbridge Is., WA
Here's a tidbit for anyone who might attempt this conversion. One of things I'm working on at the moment is adapting the RR lighting to the Hurricane wiring harness. The connector used for the lights on the Hurricane is (I think, as I don't have them in my hands yet) a "3 pin .110 connector". I just bought some on ebay from seller Kunsman68:
5 Sets x 110 3 Pin Motorcycle Connectors Honda Kawasaki Suzuki Yamaha | eBay
I will graft the plug ends onto the RR turn signal wires. I'm adding mirrors with integral turn signals, so I plan to make a Y adapter with the connector so I can add them to the front turn signal sockets too.
Also something that was not clear to me when I bought my RR headlight buckets is that there is a plastic adapter that is required to fit the H7 lamps into the headlight bulb clamps. These were not included with the reproduction buckets I bought, but I did find them at Cheap Cycle Parts. For what they are they were not cheap, about $18 the pair. There are similar adapters on ebay without the proper pins to fit the RR headlight harness for a few bucks, and one could probably make something up that would work. I just bought a used RR headlight harness and will hack the RR connectors onto the Hurricane harness.
One could just chop off the connectors and solder all this stuff together but it would make it a royal pain to take the fairing off.
5 Sets x 110 3 Pin Motorcycle Connectors Honda Kawasaki Suzuki Yamaha | eBay
I will graft the plug ends onto the RR turn signal wires. I'm adding mirrors with integral turn signals, so I plan to make a Y adapter with the connector so I can add them to the front turn signal sockets too.
Also something that was not clear to me when I bought my RR headlight buckets is that there is a plastic adapter that is required to fit the H7 lamps into the headlight bulb clamps. These were not included with the reproduction buckets I bought, but I did find them at Cheap Cycle Parts. For what they are they were not cheap, about $18 the pair. There are similar adapters on ebay without the proper pins to fit the RR headlight harness for a few bucks, and one could probably make something up that would work. I just bought a used RR headlight harness and will hack the RR connectors onto the Hurricane harness.
One could just chop off the connectors and solder all this stuff together but it would make it a royal pain to take the fairing off.
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Not sure I am following you on this one. I have the complete front wiring harness from an 04' RR which I plan on splicing into the Hurricane harness. I haven't done this yet so maybe I am missing something, but will use the RR wires and plugs for the turn signals and headlights. It's normal to have to unplug the lights when removing the fairing so not following you there. Adding additional wires for your mirrors is a simple addition to the existing harness, although you would need plugs for those but could use most any 2 pin plug or even individual spade plugs.
My wires will be soldered and then shrink wrapped so it will look like factory wiring when done with the proper plugs for the RR lights.
My wires will be soldered and then shrink wrapped so it will look like factory wiring when done with the proper plugs for the RR lights.
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From: Bainbridge Is., WA
Sorry if it sounds confusing. I do this stuff for a living and probably tend to talk too much in electronics tech shorthand. I promise pics when it is complete. It sounds like you will replace the stock sockets on the Hurricane harness with RR ones by making splices. I will instead replace the RR plugs on the lights with stock style Hurricane plugs to fit the existing three pin sockets on the Hurricane harness. Either way we will end up with the same result. I don't really like getting into harnesses much, they are always kinda sticky and gooey.
The Y adapter also lets me avoid messing with the stock harness. I'll terminate each light with a .110 plug. That way I can just remove a single mirror or just a turn signal if needed. Those plugs will plug into sockets that are parallel wired into a single plug - that's the Y adapter. That plug goes into the stock harness turn signal socket.
By the way it was nice to find a flasher relay set up for LEDs that fits the Hurricane harness too. I'm doing all LED turn, brake, tail and license lights. Might look at converting the headlamps to the new 3000 lumen Cree LEDs too. Gotta love headlights with built in fans.
Got the front brakes bled this afternoon with a borrowed Harbor Freight vacuum brake bleeder. Nice little tool, sped the process up a bit and cut down on the mess I had made with the rear brake. Now starting into the carbs. Turns out they are a little sad inside. One diapraghm has a tiny tear that I think I have managed to seal with Plasti-dip and the two needles I have pulled so far are a bit cruddy. Nothing seems too terribly worn, I think it can all be cleaned up and will run OK while I figure out what I might want to do for a more serious retune.
The Y adapter also lets me avoid messing with the stock harness. I'll terminate each light with a .110 plug. That way I can just remove a single mirror or just a turn signal if needed. Those plugs will plug into sockets that are parallel wired into a single plug - that's the Y adapter. That plug goes into the stock harness turn signal socket.
By the way it was nice to find a flasher relay set up for LEDs that fits the Hurricane harness too. I'm doing all LED turn, brake, tail and license lights. Might look at converting the headlamps to the new 3000 lumen Cree LEDs too. Gotta love headlights with built in fans.
Got the front brakes bled this afternoon with a borrowed Harbor Freight vacuum brake bleeder. Nice little tool, sped the process up a bit and cut down on the mess I had made with the rear brake. Now starting into the carbs. Turns out they are a little sad inside. One diapraghm has a tiny tear that I think I have managed to seal with Plasti-dip and the two needles I have pulled so far are a bit cruddy. Nothing seems too terribly worn, I think it can all be cleaned up and will run OK while I figure out what I might want to do for a more serious retune.
Last edited by Doc B.; Sep 11, 2014 at 11:14 PM.
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Sorry if it sounds confusing. I do this stuff for a living and probably tend to talk too much in electronics tech shorthand. I promise pics when it is complete. It sounds like you will replace the stock sockets on the Hurricane harness with RR ones by making splices. I will instead replace the RR plugs on the lights with stock style Hurricane plugs to fit the existing three pin sockets on the Hurricane harness. Either way we will end up with the same result. I don't really like getting into harnesses much, they are always kinda sticky and gooey.
The Y adapter also lets me avoid messing with the stock harness. I'll terminate each light with a .110 plug. That way I can just remove a single mirror or just a turn signal if needed. Those plugs will plug into sockets that are parallel wired into a single plug - that's the Y adapter. That plug goes into the stock harness turn signal socket.
By the way it was nice to find a flasher relay set up for LEDs that fits the Hurricane harness too. I'm doing all LED turn, brake, tail and license lights. Might look at converting the headlamps to the new 3000 lumen Cree LEDs too. Gotta love headlights with built in fans.
Got the front brakes bled this afternoon with a borrowed Harbor Freight vacuum brake bleeder. Nice little tool, sped the process up a bit and cut down on the mess I had made with the rear brake. Now starting into the carbs. Turns out they are a little sad inside. One diapraghm has a tiny tear that I think I have managed to seal with Plasti-dip and the two needles I have pulled so far are a bit cruddy. Nothing seems too terribly worn, I think it can all be cleaned up and will run OK while I figure out what I might want to do for a more serious retune.
The Y adapter also lets me avoid messing with the stock harness. I'll terminate each light with a .110 plug. That way I can just remove a single mirror or just a turn signal if needed. Those plugs will plug into sockets that are parallel wired into a single plug - that's the Y adapter. That plug goes into the stock harness turn signal socket.
By the way it was nice to find a flasher relay set up for LEDs that fits the Hurricane harness too. I'm doing all LED turn, brake, tail and license lights. Might look at converting the headlamps to the new 3000 lumen Cree LEDs too. Gotta love headlights with built in fans.
Got the front brakes bled this afternoon with a borrowed Harbor Freight vacuum brake bleeder. Nice little tool, sped the process up a bit and cut down on the mess I had made with the rear brake. Now starting into the carbs. Turns out they are a little sad inside. One diapraghm has a tiny tear that I think I have managed to seal with Plasti-dip and the two needles I have pulled so far are a bit cruddy. Nothing seems too terribly worn, I think it can all be cleaned up and will run OK while I figure out what I might want to do for a more serious retune.
Okay, I get what your doing. I have a spare carb rack for spare parts. Could send you a good slide and diaphram and a couple of needles. Send me a PM.
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Joined: Apr 2014
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From: Bainbridge Is., WA
Thanks for the offer! The tear was pretty small and way out by the edge so it might even be sealed up by the cover plate when I put it back together. I checked the repair this morning and it looks good when I flex the diaphragm. I'll check how well the slide holds under vacuum and if it turns out to be flaky I just might take you up on that. Second diaphragm looks great. Ran out of time to get the last two opened up last night. Crossing my fingers they are OK.
I didn't find a source for new diaphragms. Would be nice if one could replace the 24 year old rubber with new rubber. On the other hand maybe I should make do with what I have. My wife and my bookkeeper went through the receipts for this project yesterday. Holy smokes, I've spent HOW much on this $450 bike so far? I coulda bought an '06 RR! I'm gonna have to ride the wheels off this thing to justify it.
I didn't find a source for new diaphragms. Would be nice if one could replace the 24 year old rubber with new rubber. On the other hand maybe I should make do with what I have. My wife and my bookkeeper went through the receipts for this project yesterday. Holy smokes, I've spent HOW much on this $450 bike so far? I coulda bought an '06 RR! I'm gonna have to ride the wheels off this thing to justify it.
Last edited by Doc B.; Sep 13, 2014 at 12:52 PM.
