So I did it again… There I was quietly scrolling around the internet and I found a 2004 Blackbird that had been left stored and unloved since 2013, the owners description was spot on, I later found but he was honest about the engine block & I was to treat it as broken (it went clank, no funds to fix and was put away to grow cobwebs) the rest is just age and neglect!
We bartered a deal and I got it dropped off (looking ok but unloved) and started to pull her apart to see what the heck I just bought.
Everything perishable – had, anything that could rust was doing its own thing to varying degrees, and the engine was given its last rights, she arrived black but the log still showed her as the factory Blue, as the current black was pretty tatty and had a replacement matt tank (the black pic is “flattering” but up close it was rough) so I started to consider this as part of the refurb…
New Engine…
I returned to the web looking for a 2004 motor to keep it genuine, I found a 2004 cat B write off with a bent head/frame and did a deal with the seller for the motor and a few basic spares.
The new motor was same year and even within 2k of the mileage so I was well chuffed (good n cheap too), but as always I treated as an unknown and decided its a ground up restoration.
On inspection the bottom end seemed damn fine – usual clutch & springs plus a full check and magnetic sump bolt, compression good but split the head to get a feel for the pistons/bores/inside the head and valves – it would need a re-shim & new camchain tensioner anyway but the rest was surprisingly spot on !
Now I had a good heart for the lady! Here’s where the fun begins… (I must be nuts !)
The Rebuild…
Starting with the frame the previous owner had tried in vain to clean it back to alloy as the OEM satin black I guess had been peeling/stained/scratched up or whatever, so I restored that back to OEM with new taper head bearings and lowered it over the engine – weird combination of spacers on the ‘bird and the service manual is not much use at all (other than the odd pic). Adding the swingarm with new bearings (warning – this theme will continue) the rebuild had begun.
While I was checking the engine I had fully stripped and rebuilt the forks, the stantions had nothing but surface marks – no pitting so I got off lightly there, new seals & dust covers and good fork oil carefully measured then checked. Putting the triple tree and forks back in really felt like making progress followed by the rear sub-frame and stringing the now checked and resealed harness (usual gaps and scrapes to the cover and checking the “hidden Honda diag/assembly connector” known to ‘bird owners that they tucked away and becomes a weakness if ignored, any damp in that and you got real problems!
So onward and upward, many hours after work, sneaky 5 mins that turn in to an hour and simple jobs that turn in to the 1 bolt away for an ordeal… You know how it goes !
The Wheels…
The wheels needed some love and bearings/seals, the tyres are good for now while we rebuild her but the 10 year old rattle ‘n go gold was peeling, oxidised underneath, and just “crap” tbh.
Picked a nice metalic grey similar to OEM to go with the “blue” paintwork, cleaned them back, smoothed them, etch primer, grey main, two simple white reflective trim and 3 coats of clear…
Shocking…
Now in to the descisions, the rear shock was a Hagon so I was pretty sure it was serviceable and salvageable (yup, I was wrong!), the old brakes system was beyond recovery and too much to restore (interlinked front and rear Honda system) so decided to de-link and get HEL lines, and a few other simple ideas that would become better along the way and create other challenges too – lol !
Hagon – beyond economical repair and the vice to prove it!
I got in touch with Hagon and they did me a replacement deal – not cheap but she now has a brand new shocker.
The brake discs where not badly worn (well within tollerance) but the front pair’s float buttons where all solid so not to waste more time she got new shoes and fox-eye discs all round…
As one thing goes on – another two can follow and so it goes on, and my one-off seat cover was due to arrive! Some of the parts list that I repaired, replaced or upgraded as follows…
- LED H7 headlights
- LED mirror indicators with running lights and dip units (dips the whiite when turn is on for each side)
- LED tailight and LED reflector (tail/stop)
- Cameras front/rear – 1080p with gps/wifi download and parking cover
- Alarm
- triple tree aux plate near ignition with switched USB charger and voltmeter
- loud new horn
- white/yellow aux lights fitted after mot – spot/fog seemed a nice add
- and much more….
The Brakes…
As I mentioned earlier I decided to de-link the brakes as a “needs-must” but like most things there are various ways to do it…
I could, just replace the mains with new lines and block off the Honda link bits and dump the “beyond repair” middle pipes/kit which is simple. But it leaves you with only 2 pots on each caliper active and a 3rd that could get dirty/sticky/bind maybe?
I looked in to a trick of drilling inside the calipers and blanking the middle “link” banjo to make all 3 pots active on these calipers, the rear is no problem but the front pair would be an increase of area that could make them squishy or less feel so I found out while the CBR1100xx has a 13mm front master cylinder the CB1300 has a 14mm – ooohhh! (yup, I got drilling)
I had to make a replacement for what used to be the combined brake master cylinder that would normally be attached to the front left caliper so cut/drilled and shaped a piece of thick alloy if you look in the pic below just behind the fork and on top of the caliper mount.
It worked out a treat! – same feel but now all 9 pots are acive on a simple de-linked brakes with HEL lines and new pads/disks – I almost feel safe !
Recover the Seat…
I had on previous bikes including Cal’s cruiser used seat covers and my VFR’s I fitted gel pads so this time it was clear the OEM was worn/brittle and ready to crumble, so I decided to do the same again – however I got chatting with my cover supplier who normally only does a CBR logo for the hump area and I wanted a little something.. You will see what I asked for and it turned out better than expected.
So everything is comming together with no “major” obsticals (the odd expletives translation course, hunt the lost part and traditional find the 10mm socket session)
The big bits are in/on, the main bits are on and the fiddly items are giving in to my determination. Its starting to look like I need to sort the fairings and bits.
It turned out ok I think…
One pic is the “late to arrive” smoked inicator covers to match the tail light. I left the mirror covers and grab rail satin black for now as I was not sure if it would look too much blue, so far so good !
She then went off to pass her MOT with no advisories, happy days !
Last thing is I am adding a pair of spot/fog lights (and idiot DRL’s) – unusual as you can have this pair as white spot/DRL or yellow fogs 3 wire hookup.
