961 Birthday

ntst8

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A start to a few upgrades on my 961. The current thinking is to replace the ECU, finish oil/breather system mods incl the oil pump non return thingy, replace the ugly leaky old headlight bucket with the later classic styled one, install Motogadget indicators, replace the regulator and reinforce the battery tray.
Once all done have a ride or two to see what difference has been made and then think about the mechanical blueprinting.
Headlamp removed, starting to play with the indicators.
961 2021 Birthday (3) Headlamp Removed S.JPG
Removal of ECU, pretty much as in Richard-7's guide except...
961 2021 Birthday (7) Rear End S.JPG
My wiring has been run around behind the fuse box bracket so can't easily pull the fusebox out of the way, have to fiddle around that to get to the ECU bracket screws.
961 2021 Birthday (8) Trapped Fusebox S.JPG
Battery disconnected before removing the ECU, a couple of gremlins revealed. The sealed battery has been spitting acid out of the relief port (corroded D on the battery strap and on the battery tray and staining on the rear of the battery mat) and the battery tray has cracked at the usual spot - gusset required.
Inked961 2021 Birthday (17) Battery Tray S arrow.jpg
Ricks regulator fitted, hopefully this will deal to the battery. It appears to have been overcharging, the old reg failed the tests in the factory workshop manual.
961 2021 Birthday (19) Ricks Regulator S.JPG
Old and new ECU. the rear (left in shot) lug needs to be removed to fit into the seat space. The factory one has been removed by someone trained at the Bigger Hammer School of Engineering Finesse, it had been crudely snapped off. I will try to be a bit neater.
961 2021 Birthday (20) ECU S.JPG
Essential tools today, 2008 doesn't seem all that long ago. Light grey is not very forgiving of oily workshop hands.
961 2021 Birthday (18) Thirsty S.JPG
I am back at work already so as always progress will not be fast.
 

ntst8

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I should have this ready for stage 2 by then but aim to have it as a backup.
The 850 is the plan for Raincliff but it does have a history of breaking down just before a rally.
 

ntst8

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There is a rubber mat over the engine/under the fuel tank - possibly a splash guard due to the short front mudguard? I hadn't noticed until now that there was velcro to hold the mat to the underside of the battery tray. It might have been effective in the show room but that was long ago.
961 2021 BIrthday (25) Velcro S_LI.jpg
One of the throttle cables is getting worn on the underside of the battery tray, see below and top left in the pic above. My usual fix is to glue a piece of old inner tube on any contact spot.
961 2021 BIrthday (26) Throttle Cable Chafe S_LI.jpg
A matching pair, the coil support side is also cracked. Not easy to see, another gusset needed. Hopefully i will find a man who can tomorrow.
961 2021 BIrthday (30) Second Crack S_LI.jpg
Battery tray fitted into the tank so i can picture whether gussets/doubler plates will have any clashes. Plenty of space it seems.
I know the fixes for this have been on here but i have always struggled to visualise where and how, all makes sense now.
961 2021 BIrthday (33) Battery Tray in Tank S.JPG
 

ntst8

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Just a shopping day today.
- Battery tray dropped off for strengthening.
- 2 x Bosch Injectors ordered, should be here tomorrow, $110 ea. Will fit the heat insulator between the injector body and the head while in that area.
- Relays - $17 ea. for Narva or $33 ea. for Genuine Honda parts!! Parts are always expensive here. A note that only 2 relays are wired to all 5 pins, 4 are wired to 4 pins only, but can't get it wrong if all 6 relays are the same.
 

grandpaul

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@ntst8 I'm curious, what is under the seat hump on those bikes?

I'd have stuck the battery under there, and given the fuel tank more capacity...
 

ntst8

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Hi Paul,

the hump has two spaces with a divider between. Front section just big enough for the ECU, fuse box, OBD connector and wiring, and rear section just the tail light.
There isn't much spare room, a small battery might fit on its side in the front section but the ECU etc would need a new home then.
I agree that it would be great if the tank volume were greater. I was on the list for the alloy tank (17 litres instead of 14) group buy which seems to have become a Covid casualty.
 

ntst8

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Injectors turned up today - listed as for a 6.0 litre V8 Commodore, and i received the last 2 in the country thanks to that Covid thing.
Relays due tomorrow hopefully, may explain why the shop was gathering them from multiple sources too.
 

ntst8

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The tail unit sits on 5 spacers, very little give in them but they seem to do the job.
961 2021 Birthday (39) Rear Indicators S.JPG

New rear indicators fitted, does the arse look small with those? Motogadget mo.blaze pins, it was going to be the larger "ice" version but a late change of plans.
961 2021 Birthday (41) Rear Indicators S.JPG
New ECU and Omron relays fitted, flasher relay will need to change for the LED indicators so is still hanging loose otherwise the tail end is done.
961 2021 Birthday (42) Rear Indicators S.JPG
 

cliffa

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ntst8, looking good.

is that a reed valve on the crank breather?
 

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ntst8

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It is a reed valve, an attempt to deal to the oil in airbox issue. It made zero difference.
 

ntst8

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Staggering progress tonight, or perhaps progress staggers on...
Flasher relay fitted, the nice little mo.wave solid state item. Works with LED or filament bulbs.
961 2021 Birthday (44) Flasher Relay S.JPG 961 2021 Birthday (45) Flasher Relay S.JPG
 
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ntst8

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Pulled the rear wheel out to next get the airbox out and give good access to remove the throttle bodies.
Another sprocket gone, would be nice to find a steel replacement.
961 2021 Birthday (56) Curly Teeth S.JPG
The doubler plates on the steel chainguard seem to be doing the trick, mid mount is similar.
961 2021 Birthday (57) Chainguard Doubler Plates S.JPG
Paint on the swingarm in front of the rear wheel isn't too tough, clean and touch up needed.
Above the front sprocket you can see where the chain wears a track in the aluminium cover, time for another tidy up with a file .
961 2021 Birthday (59) Oil Bottle Bracket S.JPG
 

cliffa

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It is a reed valve, an attempt to deal to the oil in airbox issue. It made zero difference.
I suppose if you suspect that you have piston blowby, the last thing you want in the crankcase is a partial vacuum as it will just make matters worse (presumably)

It's neat though, where did you buy it?
 

cliffa

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Pulled the rear wheel out to next get the airbox out and give good access to remove the throttle bodies.
Another sprocket gone, would be nice to find a steel replacement.
View attachment 21171
The doubler plates on the steel chainguard seem to be doing the trick, mid mount is similar.
View attachment 21172
Paint on the swingarm in front of the rear wheel isn't too tough, clean and touch up needed.
Above the front sprocket you can see where the chain wears a track in the aluminium cover, time for another tidy up with a file .
View attachment 21173
Belt conversion ?
 

ntst8

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I suppose if you suspect that you have piston blowby, the last thing you want in the crankcase is a partial vacuum as it will just make matters worse (presumably)

It's neat though, where did you buy it?
It is from JS Motorsport, not cheap but seems a nice unit and to me at least looks better than the XS 650 type if it is going to be visible.
I too came to the blowby conclusion after fitting the the reed valve. Hoping to cure the engines internal issues mid year, after which the valve may do some good.

As for a belt final drive, it would be interesting but no not a fan.
 

ntst8

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Bosch Injectors and throttle body heat insulator gasket fitted.
961 2021 Birthday (64) Injectors Insulator S.JPG
Looking to drain the temp sensor swimming pool on top of the airbox. The brass plug came out with a little bit of elbow grease (2104 model so not glued in) so thinking i will drill the plug and ideally fit a hose which then sleeves through the bottom of the airbox to drain externally.
Once the engine has been apart and the suspected blow by/oil breather discharge resolved i'm planning to connect the crankcase breather to a catch bottle only. Then shouldn't need the oil drain from the airbox (?) so i may plumb through that.
961 2021 Birthday (65) Airbox Drain S.JPG
 

ntst8

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New go faster bit arrived - i have only had 1 key until now. Rob Jameison (remember him) suggested i buy a generic one, way cheaper than theirs. But UK resellers wouldn't send to NZ. Finally went to a localish Moto Guzzi dealer who could only get an Aprilia branded blank.

961 Go Faster Key.JPG

Now trying to source a new rear sprocket. Talon told me to talk to the local reseller, reseller says (via a retailer) that he doesn't stock them and seems in no great rush to say whether or when he might get some in. Not in time for our rally in March it seems. Also tried to get a steel rear sprocket, plenty of JT brand steel versions locally, but not of this style it seems. Who would want a steel version of a race sprocket i suppose.
i should have just pulled the engine down and done a proper job from the start after all. Grumble grumble.
 

gortnipper

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But UK resellers wouldn't send to NZ.

Remember...cough, cough... Youshop... cough, cough.

Now trying to source a new rear sprocket. Talon told me to talk to the local reseller, reseller says (via a retailer) that he doesn't stock them and seems in no great rush to say whether or when he might get some in. Not in time for our rally in March it seems.
I thought you were planning on taking the Ntst8 down? We would have had dueling Interstates.
 
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