'92 rebuild

[DannoXYZ]

Hmm, make sure it's 100% acetone and not that nail-polish stuff. Also ALL paint must be removed from ABS, sand, scrape, chop off all paint from surface. Try dropping a fragment of actual paint-free fairing material in there and see if it'll dissolve.

https://www.wikihow.com/Identify-Abs-Plastic

[BonelessSugar]

oooohhhh yeah the ABS im trying to melt is all coloured. I tried fairing material before and it mostly dissolved, but still not like it was supposed to. I'll post ABS and acetone and container that it's in in ~5hrs.

[BonelessSugar]

Pics

[Triple Jim]

Have you done much stirring?

[BonelessSugar]

i shake it up twice a day

[BonelessSugar]

I'm guessing the acetone I have isn't doing what it's supposed to be doing correctly, because the video danno linked has it melting way faster than my acetone does for either plastic. Went and picked up some 100% nail polish remover because it actually says 100% acetone on the bottle, where my metal container doesn't say 100% anywhere on it, just acetone. Otherwise I'm kind of at a loss. Update tomorrow with results. Working a lot. Forgot to get glycerol/glycerin to firmly check abs.

Edit: not melting. Stripped the colour real well, though. Next is to check if it's actually abs.

[BonelessSugar]

Bought a different ABS. This one dissolves.

[BonelessSugar]

Mounted tire on wheel today. I have some white ceramic beads I put in the valve stem. https://www.kawasa***************/th...g-beads.36721/ (ninja300 forum) says 1oz in front and 2oz in rear. I used this video and used this link. Video was helpful, link was not.

Propped wheel up on 2x3's and used a lever to break the bead as much as possible, then started making my way around the wheel.


Bead is broken


Using three levers to try to work the tire off the rim. Pull down on the middle, push in the right, move over the middle, repeat.


Rim is free. Light spot on tire was marked with a pink circle, heavy spot on the wheel was 90 degrees CCW from stem with rotor facing up.


Time for lube. First side was a little difficult, second one was way harder. Accomplished it from here by stepping on two levers as far into the lip that I can, and then going under the tire and slipping a third lever into the rim and pulling it over (not very far from one of the two levers, or else it doesn't work).


Finished result. Pumped to 60psi to hear both pops, then dropped to 30.

[BonelessSugar]

reassembled front caliper. trying to bleed the rear one but the bleeder screw is entirely rusted through. ordering a new one, looks to me m7x1, 26mm length.
also picking up allen bolts for the front brake resevoir, looks like 1x4-28 1in.

[DannoXYZ]

@BonelessSugar how's this project coming along?

[BonelessSugar]

@DannoXYZ

All the plastics have been repaired, but not painted. Had to add some raw plastic strips in for support on the middle of the lower cowl, it was cracked in half at the bushing spot.

Rear brake is cleaned and bled, leaving wheel off to make it easier to put carbs and airbox in and out.

Got the carb on but couldnt get the airbox on the carb and broke my aluminum fix on the carb, nbd. Last time i removed the metal springs on the airbox and did some finagling to get it on, very annoying to get the springs back on the airbox when its attached to the carb in the bike. Airbox is missing the rubber band on the top to hold it down, 92072-1196 ($30 on ebay, shesh). Did a 4hr trail ride on my other bike today. Going to get the carb and airbox on then start asking for help with starting the bike. Dumping out the old fuel in the tank and replacing it with fresh fuel to try to start the bike (tomorrow morning). I cut the carb fuel line and put an inline filter in it to try to help with the rust in the tank.

I also replaced the footpeg, then drilled and tapped the handlebar, and got new bolts for the front brake reservoir.

I need to still put all the handlebar controls back on, need to either find a video of someone doing it or try to figure it out without help. Also need to add in the coolant reservoir tank you sent me.

I have a camping trip next week so I'll be MIA after tomorrow.

I found out after mounting the tire that apparently you're supposed to replace the valve stems while you're replacing the tire... oops. Ordered new ones and new tires for my other ninjas that I haven't started working on yet.

[DannoXYZ]

hey, coming along, good job!

I never replace valve-stems if they're in good shape. You can wiggle them to see they're cracked where they go through rim. I'll replace if needed with metal ones so i'll have to do it just once.

[BonelessSugar]

I forgot the tank had rust in it so I couldn't use it to try to start the bike. I'm going to go this route again and just do multiple passes of it and completely fill the tank afterwards so I dont get rust. There was quite a lot in there when I looked. If there's any other suggestions lmk, I went through this thread for info again, and everything seemed to be contradictory with experience with people except for that method. Kreem, caswell, etc. Radiator shop is 300mi away. I do see some advocacy for POR here.

[Singh2jz]

I use a spare coolant reservoir as an auxiliary fuel tank for testing engines and such. The vacuum line connects to the vent port. Chime in if it’s not a good way to do it lol but it’s worked so far. Get something one there to run the engine while you figure out the gas tank situation.

[BonelessSugar]

How should I go about trying to start my bike? Choke? Throttle? Starting fluid?

[thedrewski86]

Ideally, you would just do full choke and start, no throttle, then ease off the choke as you can. I aim for about 3,000 rpms as it's warming up for the first minute or two.
Folks here don't like to recommend starting fluid. If I mess with my throttle as the bike is warming up it gets temperamental.

[ducatiman]

Originally Posted by Singh2jz

I use a spare coolant reservoir as an auxiliary fuel tank for testing engines and such. Get something one there to run the engine while you figure out the gas tank situation.

suggest an old, plastic lawn mower tank, el-cheapo, readily available.