How to Make a Motorcycle Cable
Making a motorcycle control cable is relatively easy and requires few tools. If the cables are to be made from scratch, the mechanic must first establish the length of the outer cable.
4 into 1 Classic Motorcycle Exhaust Systems
Of the many performance enhancing items to be made for the Japanese bikes, none were more popular than the 4 into 1 exhaust systems.
How to Make Braided Brake Lines
There are few more useful modifications to do to a motorcycle than replacing the rubber brake lines with braided stainless steel lines. For the home mechanic, this task is relatively simple.
Correct cable routing is a very important part of classic motorcycle safety. All cables, wires and lines were designed to follow a specific route.
Motorcycle Carburetion – Rich and Lean Mixtures
An internal combustion engine needs three things to operate: gasoline and air (compressed), and a spark. Optimizing the combustion is the tricky part. The spark must occur at exactly the right moment, and the gasoline/air mixture and ratio must be in the correct proportions, neither rich not lean.
Balancing Wire Wheels With Solder
Quick tip: How to balance a classic motorcycles' wheels.
Suzuki GS 750/1000 Tapping Noise
The Suzuki’s GS series motorcycles were good all round bikes. However, early versions did have one problem; some developed a loud ticking noise from the overhead cams, was this serious?
Examination of a spark plug can tell a lot about the conditions within a cylinder. From worn rings (oily deposits) to incorrect jets, the spark plug's condition is representative of the workings of a cylinder
Inside a Motorcycle Cylinder – how to Check Without Disassembly
Checking the internal condition of a motorcycle engine with a cranking pressure tester is a simple task the home mechanic can undertake. We follow the process through.
Jawa CZ Kick Start Gear Lever
Some motorcycles used a common lever for the gear change and kick start. This latter design was common on eastern block motorcycles such as the CZ and Jawa (two companies that eventually came together).
Part Out, or Buy Another?
There sometimes comes a day when we have to conclude that a bike is beyond (economic) restoration. There are two options at this point: part it out, or buy another and make one good bike from two.
Classic Motorcycle Workshop Hand-Tools
Owning a classic motorcycle often means undertaking most, if not all, regular maintenance and repairs. But the obvious problem you’ll run into when updating or when buying the first set of tools is price; for instance, how do you decide when to go expensive?
Classic Motorcycle Oil Change – Replacing the Seal
On many Japanese motorcycles, the oil drain plug doubled up as the location for the gear change drum detent plunger. This clever design worked well, but the mechanic had to ensure the sealing washer was replaced when doing an oil change.
Replacing a Broken Brake Bleed Nipple
The design of brake bleed nipples makes them prone to seizing and braking, particularly in older motorcycles. Luckily, removing a broken brake bleed nipple is relatively simple.
Motorcycle Units of Measurement
Component parts for motorcycles use a number of measurement units. In some instances, both SI and metric units are used to dimension a single unit, such as a tire.
Balancing Twin Carbs
Carburetor balancing on twin-carb engines is very important. Each carb must supply the same amount of mixture (fuel and air mixed) for the engine to run smoothly, develop good power, and maintain fuel economy
Fine Bead Blast Finish
Trying to keep a classic motorcycle looking original during a restoration can be a challenge. This is particularly true when it comes to finishes on engine cases, for instance.
Although drilling rotors will often make a classic motorcycle look period correct, the owner must consider the safety implications if the bike is to be ridden on a regular basis.
Classic Motorcycle Wheel Alignment
Checking the wheel alignment on a classic motorcycle is relatively easy. Although this is not part of a regular maintenance schedule, it should be undertaken on an older machine, especially during a restoration.
Motorcycle Weight Distribution
A tank slapper (handlebar oscillation) is a front end handling problem that can be caused by a number of issues, including air flow affected by a rear top box (tail shaking the dog), heavy rear luggage containers, loose head-stock bearings and buckled wheels.
Thread Replacement with Heli-Coils
There are a number of different options to repair damaged threads, Heli-Coil® wire inserts are one of the top choices for classic motorcycle owners.
Excessive Smoke from 2-Strokes
If you own a twin, or any multi-cylinder 2-stroke, and the clutch side exhaust system begins to smoke more than the others, this is an indication that the crank oil seal on that side needs replacing.
First Time Riders on Classic Motorcycles
Riding a motorcycle for the first time is often exhilarating and terrifying at the same time. If the bike happens to be a rare classic, the owner will be very nervous too. But there are some basic riding rules that the first time rider must adhere to that will alleviate some of the potential problems.
Classic Motorcycle Riding – Learning to Ride a Sidecar
Throughout the history of the motorcycle, sidecars have been attached to most solos at one time or another. But learning to ride these machines takes a special skill set.
Noise - Electrical
Noise - Electrical
Custom Helmet Painting
Personalizing riding gear by painting helmets is something motorcyclists have done since the very beginning. The home mechanic, with access to basic painting equipment, can transform a standard helmet into a custom designed unit.
Flywheel Removal with Pullers and Extractors
Special tools are essential for certain jobs on classic motorcycles. One job in particular is removing the flywheel from the end of the crankshaft.
Motorcycle Seat Re-covering
For many classic bike restorers, having the seat recovered is a must. Removing the old cover is relatively simple. However, before paying to have the seat professionally re-covered, the owner should check to see if there is a cover available, or a complete seat, as a spare part.
Classic Motorcycle Cruise Controls
Cruise control systems have been around for a number of years in various guises: throttle lever lock, push button, and more recently computer-controlled electronic devices.
Learning to Drive with a Trailer
Having the knowledge to drive a motor vehicle with a trailer attached has many advantages. For the classic bike owner looking to take his classic to a show or to a race, etc., having the knowledge to drive with a trailer is essential.
Making a Bobber
Done properly, a bobber is a motorcycle that has had unnecessary components removed (unnecessary in the opinion of the owner) and is styled to the owner’s taste—no rules.
Motorcycle will not Start
There are many individual components on a motorcycle that can, if broken or damaged, stop the engine from starting. But in essence, an internal combustion engine needs three things before it will run.
Classic Motorcycle Tools, Air Powered
At one time, air tools were used only by professional shops or race teams, but today, anyone with a workshop should consider using them.
Motorcycle Final Drive Ratio Changing
Many classic motorcycle owners change their bike’s gear ratios. This is particularly true on racers, but it does apply to street bikes too.
Motorcycle Jobs for Winter Time
Motorcycle Jobs for Winter Time
Classic Motorcycle Hardware
Modern hardware, and locking compounds, can almost eliminate items coming loose on a classic motorcycle due to vibration.
Checking Motorcycle Head Stock Bearings
The vast majority of steering head bearings used on motorcycles are of the tapered roller variety. The free play in this type of bearing is controlled by the amount of torque applied to the clamping nut—the greater the torque, the tighter the steering. Checking these bearings is a simple task.
Classic Motorcycle Engine Parts Examination
Motorcycle parts can be examined in a number of different ways. These include examination of a part (or component) by visual means, pressure test, NDT'g (Non-Destructive Testing), measurement, inspections for color change, and a touch test (checking for roughness).
Mechanicing on a Classic Motorcycle
Whatever the reason a person does his or her own mechanicing, there are some things that they should not do during the process.
Swapping Motorcycle Engines
Motorcycle engine changing, or swapping, has not been limited to café racers. Many motorcycle owners have created their own versions of the ideal motorcycle by replacing the stock power unit—some out of necessity, some by choice. However, although it sounds simple to do, fitting an engine into another manufacture’s frame is not easy and there...
Making a Motorcycle Wiring Harness.
Replacing the wiring harness, or loom, on a motorcycle is a relatively easy task but can be time consuming.
Riding on when a problem arises on a motorcycle can be dangerous. Sometimes it is imperative to pull over and check.
The evolution and development of motorcycle wheels have typically followed performance increases. But not all new designs were successful.
Testing Motorcycle Components
During an engine rebuild (overhaul) or restoration, many of the components must be tested to ensure they meet the service recommendations of the manufacturers. Luckily, most of the tests are relatively simple to do.
Checking Motorcycle Parts and Settings
There are many checks to do on a motorcycle. Learning to check certain components and settings is how most motorcycle owners learn about the mechanics of their machines.
Test Riding Motorcycles
For motorcycle enthusiasts, riding a motorcycle is pure pleasure. However, occasionally it will be necessary to test ride a motorcycle for reasons such as to road test the carburetor settings, for instance.
Replacing Spark Plugs
Changing a spark plug is probably the easiest job on a motorcycle, but if you've never done it before, a little guidance is always welcome.
Adjusting Motorcycle Cables
Adjusting the free play of motorcycle control cables is a relatively simple job, but there are safety issues that must be considered.
The Honda RC 161 Replica
Making a replica of any engineering piece is challenging. Making a replica of a factory racing motorcycle is especially challenging, but this is what the employees at the Barber Vintage Motorcycle Museum did when they built a replica Honda RC161.