Not Much of an Update

Other that deciding on the basic rebuild on the last post, and discovering that the paint job on the plastic side panels is exceedingly tough, not much has been done.

Yes, the plastic parts. I purchased a 320 grit wet/dry sanding sponge to experiment with the panel paint. The thought was to remove the paint, repair the plastic and start the carbon fiber wrapping process.

Not that easy. After 30 minutes of scrubbing, the sanding sponge did almost nothing to the paint. So, a fellow at work suggested I simply repair the plastic, scrub the paint with a coarse sanding medium, not removing it, just roughing it up, and then start laying down my black, clear, carbon fiber, clear, clear, etc...

The only concern I have with that, is that the plastic panels will end up being slightly larger than stock and may not fit. Well, considering the condition of Vixen right now, that may be the least of my concerns.

I did manage to get some tar off the radiator and rear fender. At the recommendation of a fellow I know at AutoZone, I tried Rust-Oleum Wax & Tar Remover. While it doesn't just turn the tar to jelly, the chemicals do loosen the tar enough to scrub it off with a brush.

Also, I will soon have a parts inventory and refurbish list completed. It is a form of spreadsheet; one for each parts fiche page. It will help me keep track of what state all the parts are in. When it is done, it will be available here for your downloading pleasure.

The Reconstruction Begins...

Unfortunately, even after searching, not only could I not find a decent picture of a VX's plastic panels on-line, but I could not locate my camera! The lack of photos on the 'net does not surprise me. Considering the fact that I just finished a move, it is no wonder I can't find my camera.

But, it is time. The plans are roughly set and I am going to get started. Here are the plans:

1. Color Scheme: Frame, radiator guard and swing arm will be fire engine red. Engine will remain aluminum. Exhaust will be matte black, eventually being ceramic coated. Most chrome will be black unless appropriate. Plastic parts will be cleaned, stripped, painted black and coated with carbon fiber composite; finished off with plenty of clear coat. Tank will be the same as plastic pieces; black, wrapped in carbon fiber and clear coated. Honestly, I have not decided if the wheels should be painted or not.
   
2. Basic Concept: Most of the mechanics will remain the same as necessary. The goal bike will be a sport tourer style where comfort and functionality will be paramount. This bike should ride well on asphalt and gravel.
   
3. Lighting: Incandescent turning signals will be replaced with high intensity LED. The typical single VX800 headlight will be replaced with two HID lights.
4. Fairing & Additional Plastics: The dual headlight mount will likely be custom. The headlight cowl and small sport-like fairing will be make similarly to the method, builders of the KR2 use. A positive mold will be made of foam and fitted to the bike. Then it will be built up with carbon fiber and epoxy. The black color scheme will remain.
5. Engine: If possible another VX engine can be merged with mine. If that is not possible, an Intruder 800cc engine will be used.
   
6. Saddle: Unless a saddle in great condition can be located, a Corbin will fit the bill nicely. Corbin's black saddle suits the basic color scheme. Not sure about the purple piping though...

So, first things first. Now that my move is complete, I will start cleaning and cataloging the parts I have, and cleaning and working on the plastics.

Oh, what a wonderfully strange path this is going to be!

Little Update

Well, not much forward momentum on Vixen. There do seem to be some inexpensive parts bikes out there. With my recent move and my daughter starting her second year of college, money is exceedingly tight.

An interesting little thing I did learn from the VX800 e-mail list was that there are likely less than 10,000 VX800s on the globe. That may seem like a lot, but in the grander scheme, it really isn't.

According to some statistics at www.webbikeworld.com there are roughly 204,100,000 motorcycles in the world. So, on average there are 20,410 motorcycles for every VX800. Given that the VX was sold in the United States for only a few years does indeed skew the numbers.

What does this boil down to? Well, there just aren't many VX800s around anywhere.

OK, ok, ok... Getting Dirty Again

After a little discussion, the final decision has been made. I keep Vixen. The end of this path is unknown. If Vixen is rebuilt and running, there will likely be no worry about the end of the path. We will simply blow past it.

OK... Links for Motorcycle Restoration, Parts, Research, Repair and other information.

Jaxed Motorcycle Craigs List/E-Bay Search Tool. This is a pretty cool little tool that allows the user to search all locales in Craigs List and e-Bay. It is pretty good, but does seem to miss a few things on the e-Bay search.

Cheap Cycle Parts.com Well, maybe not cheap, but definitely reasonable.

Suzuki VX800 Discussion Forum. Not much traffic but some good information.

VX800.net Mailing list, links, FAQs, information, manuals, pictures and other stuff.

Finish Restoration. This is a nice place to go for information about restoring the finish of a motorcycle and reviews of products.

Vintage Japanese Motorcycle Restoration. Some interesting points about motorcycle restoration. This is a Geocities site, and as such, will be coming down soon. At one point, I should copy it.

Good News - sort of...

After inspecting the cylinder, getting some feedback from others and contacting a local engine repair shop, there is some good news... The cylinders and heads are likely repairable! The cylinders will need to be bored out. Pistons will need to be replaced with new ones to fit the cylinders. Valves need to be replaced. Valve seats cleaned and honed.

Good news for someone wanting to rebuild her. Alas... I think the conclusion that she may be too much for me is settling in. She could be a great bike, but alas my time is limited. Maybe it is time for Vixen and I to part company.

Wrenching the Heads and Cylinders

You want to see something more gruesome than the river sludge picture? OK... Here it is...

After a particularly trying day that is far beyond the scope of this blog, I drove the cage to the local AutoZone. In exchange for two liters of old used oil and about $30 I picked up a new pair of vice grips and two pairs of snap-ring pliers. The successful removal of the heads from cylinders required the extraction of the cam chain tensioner spring. Each one has a strong spring on a shaft mounted in a sort-of ratchet mount. The spring is held on the shaft by a little snap-ring.

So, I get the pliers put together and guess what... too big. They wouldn't fit into the rather confined space where the cam chain tensioner is. So... A large blade screwdriver snapped the rings right off. Not that they are usable again, but by removing the springs, the head and cylinder could be separated.

OK, more bad pictures...

The front head may be recoverable but forget those valves.

A little scrubbing with parts cleaner and brass cleaning brush yielded marginal results, so the front cylinder goes in a bucket of parts cleaner for the night. Hopefully that hard crusty grime is not rust. If it is, I don't think that cylinder is recoverable.

Stay!

And the other cylinder and head you may ask? In pretty good condition I think, given the circumstances...

Why is there river sludge in the engine?

Please tell me... Why is there river sludge in the front cylinder?

The rear piston and cylinder look pretty good for not operating within a year or more.

The cylinders and heads are free! Apparently using daily sprays of penetrating oil for a few weeks caused the piston and cylinder to release their unnatural hold on each other. It was a surprise, really. I wanted to lift the engine onto a work bench. Working on an engine setting on the ground is simply not very good on my knees. I am still taking ibuprofin for the pain caused by my afternoon of work a few weeks ago.

Anyway, I gripped the cylinders, thinking the whole engine would lift. I wish I had a camera on my face when the cylinders just slipped up and off the pistons!




Looks like I have my work cut out for me. Hopefully I will not need to split the engine case, but first things first. The pistons, heads and cylinders need to be completely disassembled and checked. Hopefully they can be restored but I have a bad feeling about that front cylinder and piston.