Neal's mods/maintenance, 2017

[Nails]

Okay, I'm finally ready to show you my bike. I bought this '97 last March. Of dubious provenance, but just 27K miles.

[Nails]

I did a lot of plastics work. Here's one of the side covers. I used a Dremel with a wire brush to carve out a 1/16" kerf, and backfilled with ABS cement. Here's the inside. I finished the outside with normal painting stuff.

It had maybe a zillion cracks like this, especially in the top trunk. It also had a gaping wound at the left fairing corner. I had to bind it back together with a clove hitch. The ABS cement is really strong.

[Nails]

I also moved the cruise control to the fairing. Here's how those holes in the fake tank came out.

The white is code 5111, same as my '86 GMC pickup. I put some subtle pearl sparklies in the clearcoat. The black is rattle-can bedliner.

[Nails]

Cutting to the chase, here's the cockpit. On the left lower fairing are three light and a push switch. One lights when the fan is on. The rest are the cruise lights/switch.

The left handlebar switchset no longer has that second story of radio switches -- I axed all the radio crap. The "tape/radio" switch is on the first floor. It's now the cruise on switch.

I fabbed the vent where the radio used to be. It blows in where the Kawa logo used to be on the windshield cowling, just above the headlight. Honestly, it wasn't worth the effort -- blows about as much as the four normal vents. But at least it isn't a hole in the dash.

Also fabbed that map holder.

The handlebars were meant for an old Triumph T140. About 4" narrower (my hands are out of the mirrors). 30" wide, 8" tall, 7" pull-back. I absolutely love them.

[Nails]

I got rid of pretty-much all the insignia, mostly because that gold and silver crap reminds me of a golf cart. I'll tell everyone that it's a Goldwing with a Fireblade motor swapped in.

The windshield is about 15.5" tall, above the weatherstrip.

Notice the new vent inlet, fabbed from 1/8" ABS sheet. I can make it prettier later.

I resurrected the lower fender light. It has bright LEDs. The trunk has normal-bright LEDs that do that flashing thing.

I partially re-upholstered the back rest -- replaced the three pieces that face to the sun (were cracked).

[Nails]

Less picturesque:

• - Replaced all the fluids including shock and fork oil.
  - Replaced valve-cover gasket, and "streamlined" the reed valve stuff.
  - Checked cam chain tensioner and replaced gasket.
  - Replaced the plugs.
  - Cleaned carbs in ultrasonic cleaner -- they were nasty. Replaced lots of rotten plastic bits. Adjusted the floats.
  - Fabbed a tool to adjust the pilot jets. I'll talk about that in a different topic. I have them 2.75 turns out.
  - Lubed/adjusted all the cables. Now the cruise works.
  - Replaced radiator o-rings, and un-squished the overflow line so it'll actually flow.
  - Fixed the speedo (23-tooth deal).
  - Fixed the temp gauge (ground).
  - Fixed the fuel gauge (put gas in it).
  - Resurrected (so far) fork seals that leaked so bad that they douched the brake.
  - Cleaned the front brakes. I'll get new pads later. They stop fine now.
  - Repaired a heinous smash in one of the headers. This involved drilling a hole in it and slamming it with a slide hammer (had to be hot). The torch-weld didn't go all that well -- kinda gorilla (big, strong, and ugly). Reducing flame, Solar Flux B. I'm sure it flows better now.
  - Synched the carbs.
  - Replaced all the filters.
  - One of the fork tubes was about 1/8" taller in the triple clamp.
  - Replaced a perfectly-fine Dunlop 404 front tire with an M66.
  - Got about 5/8 turn out of the headset bearings.

I'm sure I'm forgetting lots.

I've only ridden it about 100 miles, all before this work. Hope to take a long ride very soon, but we just got a ton of rain and I'm a little afraid of the muddy roads getting out. (I broke a rib a little over a week ago.) But I do plan a very long ride very soon.

[cranky]

... looks good!! Now put in the tie bar that goes between your crash bars
to strengthen 'um up!!!! I think I have the same map holder, it holds
a 8 1/2x11? I used velcro tabs....

[Nails]

Now put in the tie bar that goes between your crash bars

Mine were quite bent -- used a hand-held hydraulic unit to push them close to straight. I think they're mostly cosmetic, to hold those foot pegs. (That is, to hold your feet right in the hot air from the radiator.)

I think I have the same map holder, it holds a 8 1/2x11? I used velcro tabs....

Mine is a funny shape, with wide elastic to hold the map in. (I finally have a use for these bifocal sunglasses -- a gift.)

[cranky]

... the tie bar REALLY firms up the crash bars!!!!! Highly recommend... JM2C
... your scoot is lookin' good!!!!!

[Nails]

I just rode about 150 miles. Pretty hard going: 80 MPH on the freeway in the mountains, 5500 - 7500 feet elevation.

The forks are mushy. I'll go up to 15 PSI. And I'll dream of springs of steel instead of noodle. I can live with it. Dex III front and back worked superbly.

The engine periodically seemed to "load up" -- power loss and miss. This happened on the steepest up-hills, and only when it had been working pretty hard already. (It pulled similarly steep hills just fine if it had not just been working hard.) I tried downshifting, but it was still weak, initially. Then in just a couple seconds, it started pulling hard again. Likewise, I got off the freeway after a difficult stretch, and it ran poorly at neighborhood speeds for a couple hundred feet, but then ran great. Temp never went over that long line near "cool". Fan never came on (low speeds). (About 70F today.)

I thought at first it just didn't have enough power for these hills -- the cruise kicked off, and twisting the throttle did nothing. But then noticed that it waltzed right up other steep hills.

I didn't refill the tank, but it burned down to a quarter tank in a bit over 100 miles.

The idle isn't as smooth as I'd like. It runs rough at 1500-2500 RPM, sorta like the roughness of a huge cam. Not a big deal -- still plenty driveable.

I suspect that this is an elevation/jetting issue, and I'll try again without wringing its neck. I don't think it'll be a problem in the flatlands at all -- I'll check that soon, too.

Besides that, I'll probably want some kind of butt pad. My back got stiff, but I'm definitely not used to relaxing on it. I'm not yet at peace with the floorboards, h/t shifter, or twist grip that moves by itself.

It was incredibly smooth in every way. The handling was very good, but with a minor tendency to grab tar snakes &etc. I rode most of the way with just my left hand, given that I was confused about what to do with my right one anyway.

I'm sure I could do 150 miles like that, four or five times a day. But maybe not too many days in a row.

[voyager55]

You need to replace rear shocks & fork spring with Progressive's

[cranky]

... about the seat... I put an Airhawk on mine, found it to be warm/hot,
and I'm fond of wooden beads, so I put a bead cover over it to cool it down,
and the two work quite comfortably... FWIW

[Nails]

That off-idle stumble got worse. But I got most of it dialed out by turning the pilot screws in. Now at 1.5 turns out, and will go down to 1 tomorrow when the motor is cool. My custom little screw-driver thing works so I can open them back out, as necessary when I come off the hill. I think factory settings were 2 turns out.

Over-drive and cruise control might not be the best idea for steep mountains. It pulls much better with the leaner pilot -- cruise doesn't cut out nearly so often. And after more than 80 miles I still have 3/4's on the gage -- much better than my first ride (about 35 MPG). (This confuses me because most late carb bikes were major lean.)

The forks got a lot better with just a little more air.

The radiator flush came out about as gross as the original fluid. So I'm doing a second flush.

I'm fond of wooden beads

I like this discussion, even if dated: http://www.motorcyclecruiser.com/five-m ... s-compared. Gives a good rationale to diagnosis whatever problem you're having way down south, and picking the right kind of pad to address it. I have a bead thing on order. I've been across the country on a stock seat, and don't think I really need much now.

Tomorrow, I plan another test run of a couple hundred miles into lower elevations (maybe 4500 ft).

Plan to leave on long solo ride on Sunday. Besides fussing with the pilot screws, I'll fabricate some bags to fit on the passenger footpegs, one for my tent and the other for my sleeping bag. But I'm trying not to talk about things I plan to do because that's just talking. I'm just trying to say that I'm fussing to get out the door ASAP.

[Nails]

So, I'm jetting home when other drivers start pointing and carrying on. My left side-bag cover had blown off. I recovered it intact, and even found everything that was in the little cubby hole unit.

I had to unlock the latches to put it back on -- they're obviously bent loose. It's scratched up pretty bad, but I have like a half gallon of that white paint left. So, just a day's work to put it to rights.

The irony is that one of today's errands was to the hardware store. I had the stuff to make those leashes things, right in the bag that blew open. Sheesh.

I'll also have to take the carbs off yet again. The pilot jet isn't getting it. Something else is wrong, like an enrichment valve stuck open, the pilot jet or circuit screwed up, I don't know. Double-sheesh.

[Jimvoyager01]

You are a work-a-holic...you also need to put a leash of some kind on the side covers and also keep them locked when driving..your bike looks great....what a lot of work..congrats

[Nails]

I s'pose next you'll try to tell me that you got your XII to ride it, not to work on it.

[Mr Jensee]

Neal I been there done that with the old GS Suzuki. The reason I ended up buying the ZRX Kawasaki was that I was tired of working 2 hours on a bike for 1 hour of riding. And the fact that the money I spent didn't equate to any enjoyment. The Voyager has been a heaven sent motorcycle. It has needed so little attention for a motorcycle as to be scary. Anyway, besides the fact that I am more partial to red than white (had 3 white cars over the years and hated the color) Your Voyager looks very nice. Heck if it had red and blue lights on it you could pass for a motorcycle cop on it. Any chance you are going to take it to the rally next year in Kerrville? You have plenty of time to sort it out. I still think this is a carb issue. You might think of sending them to Carl in Florida and have him sort them out and set them. If nothing else he may have a finished set he can swap you for them. As for that vent replacing the radio, I could have told you that. The best thing you can do if you ever get around to replacing the windshield is to have them install a Goldwing type vent in it. It is a much better alternative and you can close it in the winter.

[Nails]

It has needed so little attention for a motorcycle as to be scary.

I look forward to that day. I have plans for next year's upgrades (can't afford it now), but hopefully that'll be it. I'm sure tired of fussing with it now.

more partial to red than white

I honestly don't care; and I have to paint my truck anyway. So, white it is. (Okay, it is filthy dirty after riding in the rain yesterday.)

you could pass for a motorcycle cop on it.

Maybe from a distance. But I've ridden (dirt bikes) with my neighbor, a SWAT cop and in charge of the Santa Fe motorcycle cops. He has scary hands and arms. I don't.

Any chance you are going to take it to the rally next year in Kerrville?

I was thinking of it. But I'm sorta allergic to big groups. What Texans would call a "bunch quitter".

"New Mexico: so far from Heaven, and so close to Texas."

I still think this is a carb issue.

Me, too. I have them most of the way off. I bet I got something in there, given that I had to screw around with them a lot after initially putting them together. Or maybe a float is bent into something that messes with it. I'm sure it's something stupid like that because it runs so well around this problem.

The best thing you can do if you ever get around to replacing the windshield is to have them install a Goldwing type vent in it. It is a much better alternative and you can close it in the winter.

I was basically copying that: putting the inlet in a high-pressure zone and the outlet in a low one. (I think it decreases the wind pressure against my back.) It would work really swell if not for constrictions at the fairing. And I didn't want just a blank piece of plastic where the radio was. I've figured out a way to close it, but really want to quit screwing around and hit the road.

[Mr Jensee]

FYI Neal, I just got a complete backup camera and monitor for my car on a bidding website called Tophatter.com. They keep having a car stereo on there and you can get it for a ridiculously low price. I paid $26 total for the camera system. Gotten a few other items on there as well like digital smart watch for a dollar. You might want to look at the site when you are not busy. Easy to register on there and you don't need a credit card to register.

[Nails]

Thanks, but the radio I took off works fine. (Clarion, but not stock.) I'll put it in some cage. Don't want no stinkin' radio.

I got that cover (the one with lofty intentions) repaired and painted, along with the hood of my truck. Now to sort the leashes.

The carbs are off, but I might not get into them today. Planning instead to make those bags for the passenger footboards, using naugahyde like the seat with some plastic stiffener inside and simple velcro closures -- will have typical stuff-sack cablelocks inside. I think I have a way to tie them on well, including a strap across the passenger seat. I'll probably sew a smallish bag to that webbing, not too wide to interfere with those cover cubbieholes, and not too tall to get in the way of opening the trunk enough. One side for the tent, and the other for the sleeping bag, with some rain gear in the seat bag. (I mean, I'm really looking forward to showing them off ;) I bet I can get them together, at least through the bottoms of those bags, tonight.