1982 Honda Passport Restoration Part 2

Cody, this post about my 1982 Honda Passport Restoration is for you!

I finally have my 1982 Honda Passport Restoration 99.5% done, at this point all I’m waiting on is some custom made decals. Apparently the tank decals for the blue paint version were a one year only special and are completely unobtainable as N.O.S or reproduction parts. Yes I’ve checked every supplier in North America, Europe, and the Orient, so unless you actually have a set in your hand to sell don’t bother telling me to check with so and so because I already have.

A reader named Cody picked up one of these in boxes and is putting it back together and asked me to share the detailed pile of photos that I took as I disassembled & reassembled this bike so I’m going to put them into a gallery here for all to see. In addition to gleaning all of the free information available on the internet you really should get a service manual. I use the Clymer Repair Manual M310-13 because it covers every small Honda with the horizontal engines up to 1999. Keep in mind as you peruse this gallery of wiring harness connector images that this is a factory 12 volt model with electric start. 1981 and older models are all 6 volt and may be different .

This is all of the pictures that I took as I was tearing it down, I frequently referred to these and the service manual as I was re assembling this little Honda Passport Restoration project. I’ll post the pictures I took when putting it all back together next.

Peace Y’all

Is A Lithium Motorcycle Battery For You

Lithium Motorcycle Battery Pros & Cons

If you have not heard the buzz about lithium batteries for motorcycles then you have probably been hiding under a rock somewhere. There are many different brands available, and although prices have dropped some you may have noticed that they command a premium price. The question for most people is lithium motorcycle battery worth it? Most of the time yes, but sometimes the answer is no.

Of course there are a number of advantages and some disadvantages of lithium batteries in general. The single biggest advantage they have for the motorcycle restorer or customizer is that they contain no acid. There’s nothing worse than to have your battery burp a little acid out through the overflow tube and dribble it all over you freshly restored paint & chrome. Even if you carefully route the vent tube the acid still seems to corrode the battery box, frame etc.

Figure 1 Battery acid damage to a Gold Wing

<lithium motorcycle battery>

For the collector & show bike enthusiast who does not ride their motorcycles very often, a lithium battery has a very slow self-discharge rate. Especially on older motorcycles that have zero current draw when the key is switched off a fully charged lithium ion battery will usually maintain enough current to start the motorcycle for up to a year. Please note that it is recommended by all manufacturers that you disconnect and remove the battery for storage. If your motorcycle has any current drawing accessories such as a clock or an alarm system the battery must be checked & charged on a regular basis if you plan to leave it connected to your motorcycle.

In racing or other high performance applications lithium ion batteries have the advantage of weighing much less any other currently available battery configuration with equivalent specifications. I cannot recommend them for total loss ignition systems on race machines unless you are willing to be extremely diligent about checking and recharging them, and you accept the fact that this is basically a non-warrantied experimental use in the eyes of the manufacturers. If your racer has a charging system that meets the minimum charging requirements of your battery then you should not continue to handicap yourself by running a heavy lead acid battery.

Customizers love these batteries because they can be installed in any position even upside down. There are a few different from factors, most appear similar to a standard battery, but there are a few oddly shaped batteries available. Li-ion batteries are much smaller & lighter making them much easier to hide in café racer bum stops or under seat trays.

Figure 2 Conventional and Shorai Lithium Gold Wing batteries for comparison

<lithium motorcycle battery>

Warranties are usually better on these batteries running on average 3 years from most suppliers if they are installed in a factory recommended vehicle with a good functional charging system.

This leads to the biggest caveat of them all. Your motorcycle or other powersports vehicle must have a charging system capable of maintaining a steady charging rate of 13.6-14.4 volts during operation. If you have an older motorcycle that has a marginal charging system that is not capable of maintaining this charging rate and you want to run this type of battery some charging system upgrades will be needed. If yours is a fully functional mint condition classic motorcycle with all original parts, I personally would not change it just to run a li-ion battery. For one that is a frequent driver, or just needs a new charging system, look at some of the aftermarket upgrades available, it might be worth your while upgrade your charging system even if you don’t choose a Li-ion battery.

With proper precautions (see the manufacturer’s instructions) these batteries can handle some water spray or a very brief dunking, if you frequently run long deep water crossings on your dirt bike or take your atv and drive it around in the water with nothing but the snorkel sticking up above the water then these batteries are not for you.

Another factor to consider for some is that if something goes wrong & your battery goes dead away from home it can’t be jump started. Once discharged below a certain point these batteries have to be charged back up with the manufacture’s recommended charger, or you risk damaging the battery. So if you’re the life of the party & plan to use the stereo system in your Gold Wing to provide music for the whole campground until late at night & then get your buddy to give you jump start the following morning so you can get home then you shouldn’t even consider a lithium battery.

Since this was published in the Vintage Japanese Motorcycle magazine I must note that if you need a six volt battery, at this time the only manufacturer offering a six volt lithium motorcycle battery is Shorai.

Cold weather operation is a little different & takes some getting used to. When the temperature drops below freezing a li-ion has very different operational characteristics. They actually require a bit of a warming up period to deliver full voltage. For my own personal driver, a 1980 Honda CB650, when the temperatures are at or below freezing I will switch the key on and make sure the headlight is on high beam for about 30 seconds before hitting the starter button. If the engine turns too slowly to start I let go of the button and wait a few more seconds at which point the battery is fully warmed up and will spin the starter normally.  It’s just a little thing & I realize most people are not masochist enough to ride a motorcycle in the freezing cold if they have a car, but it is a difference in the behavior of lithium & lead acid batteries that you should be aware of.

To me the advantages of the lithium motorcycle battery outweigh the disadvantages and I hope that this gives you enough information to help you make an informed decision about whether or not you want to purchase one.

This article originally appeared in the Vintage Japanese Motorcycle Magazine in 2015. To learn how to join the club and receive this fine publication 6 times a year visit http://www.vjmc.org

Disclaimer; Motopsyco is an authorized Shorai battery dealer and will be more than happy to help you with selection of your new battery, so if you can’t figure out which one you need from this battery finder link, feel free to contact me by email at motopsyco@motopsyco.com.

 

Cheap Fake Cad Plating & ABS Plastic Repair

 

There are two things that are commonly found when working on old motorcycles, one is cadmium plated parts that are faded, rusted or discolored somehow, and the other is broken or cracked mounting tabs on plastic parts such as air boxes or side covers. Today we’ll learn how to do a reasonably good job of creating cheap fake cad plating with spray paint. Then we will tackle a minor repair of some ABS plastic parts. Most of the black plastic parts on motorcycles are ABS and on some such as early sport bikes such as EX250 or 500 Ninjas the bodywork is also.

Cheap Fake Cad Plating

Passport steering lock to get cheap fake cad plating

Let’s start with this steering lock that goes on my 1982 Honda C70. In the picture it doesn’t look too terrible, but this was after washing it in the parts washer with a Scotchbrite pad to get rid of some light rust.

Duplicolor adhesion promoter

Once it was dry I taped off the key slot and sprayed on a couple of coats of adhesion promoter.

chrome spray paint for cheap fake cad plating

After giving the adhesion promoter about 8-10 minutes to dry I gave the part a couple of coats of metallic “chrome” paint. This paint doesn’t really look like chrome but it really is a very bright silver.

Passport lock with chrome paint

After allowing the chrome paint to dry thoroughly, take a can of the metallic “gold” spray paint and from 18-20 inches away lightly fog the gold paint over the chrome. Just do one or two light coats. the idea is to lightly tint the part with gold but not to completely cover up the chrome.

gold metallic spray paint for cheap fake cad plating

It’s really best to do this in a well lit place so that you can see when there’s enough gold on the part and stop spraying it.

how to cheap fake cad plating

Here you can see my cheap fake cad plating next to one of the well sheltered original cadmium plated brackets from this same motorcycle. Naturally if you plan on having a 100 point national show winning motorcycle, real cad plating is the only way to go, but for your average rider or local bike night hero this is a nice inexpensive way to get a clean authentic look to parts that should look cad plated.

ABS Plastic Repair

A major source of aggravation are cracks in plastic parts and or mounting tabs broken off of them. But since since a lot of these plastic parts are made of the same ABS material as sewer & drain pipe there really is quite a simple solution. Glue them back together with common ABS cement that you can find at any local hardware store. The air box on this little C70 that I’m working on had been reinstalled at some point in the past without the metal spacers that are normally used to secure such parts to the metal frame without damaging it. The result was that one mounting tab was split & the other one was broken completely off.

fix motorcycle abs plastic parts

To repair the cracked side was simple enough, it jut needed cleaning up and having plenty of glue applied. For the other side that was completely broken out I put a standoff with a washer in the hole & gave it a good coat of cement, permanently attaching it to the air box. You can also buy ABS plastic sheet & use that to fabricate repair patches, replacement tabs & even custom parts that can be glued together using ABS pipe cement. Once you are done & the glue is dry it can be filed, sanded or even painted over just like any normal plastic.

Hopefully these two tips about cheap fake cad plating & abs plastic repair will help someone out, until next time.

Peace Y’all

 

 

Honda C70 Passport Restoration Part 1

Honda C70 Passport Restoration The Beginning

It all started out innocently enough with me picking up this little diamond in the rough. It obviously hadn’t run in a while and was very weather beaten. Initially I had no plans to do a complete Honda C70 Passport Restoration but you know how these things tend to snowball.

Dilapidated Honda C70

With a little help from my beautiful assistant it was soon running like a top.

Pretty lady spinning wrenches Honda C70 Passport Restoration

Initially I had no plans to do a complete Honda C70 Passport Restoration but you know how these things tend to snowball. Let me go ahead and be perfectly clear from the start, this is not intended to be a 100 point purely stock restoration. The goal here is to produce a very nice looking scooter to use for transportation at larger events like the Barber Vintage Motorsports Festival or the Destination Eustis Motorcycle show & swap meet.

After cleaning the carbs, adjusting the valves, changing the oil etc. I took the little thing out for few a test runs and am very pleased with how it runs & drives despite the fact that it had dry rotted and mismatched tires on it. So I started ordering the pieces it was missing such as the chain cases. Where the original equipment stuff is available for a reasonable price I’ll use that, when not there are plenty of reproduction parts available on the internet from Thailand and other countries. The quality of the reproduction parts is all over the map, so be prepared to ship some things back or tweak them to get everything working and looking good.

C70 reproduction Chain case

Then one evening a few days ago I lit a fire in the heater and started pulling it apart.

In My Happy Place

One of my favorite things to do as I am pulling a bike apart is to take lots of pictures. Thanks to digital photography it is now easily affordable to document every nut & bolt that you remove if you want to. On older bikes like this that use a lot of bullet connectors it is a great idea record every single wiring connection. Sometimes there are different colored wires that attach to each other that you may not remember otherwise. There are also incorrect wiring diagrams in some service manuals for some machines so every bit of extra information helps. Plus when you put it all back together & it works right the first time, your friends will think you’re a genius!

Yes I really do use Shorai batteries for damn near everything, They’re especially great for motorcycle collectors who often let their bikes sit without running and there’s no acid to boil over and ruin your shiny new paint job. Last year I wrote an article for the Vintage Japanese Motorcycle Magazine detailing the pros & cons of using lithium batteries in motorcycles, that article will probably show up here on the blog in the near future.

Motopsyco sandblasting a Honda Passport C70 Restoration

Since there was quite a but of surface rust & some light pitting the frame & forks were taken down to bare metal by sandblasting. Since I did not remove the fork from the frame I very carefully sealed off the bearing cup areas to keep the sand out.

zinc dichromate primer

After it was completely stripped, it received a few coats of zinc phosphate primer for maximum rust protection.

Ford blue engine paint

Since this is to be a parts runner and not a show bike instead of buying an expensive urethane paint in the original Honda Angel Blue I opted for 3 cans of Duplicolor ceramic engine paint in Ford blue. These paints are very durable & hold up quite well to gas and oil spillage.

Honda C70 Passport Restoration Starting the Assembly

Motopsyco Honda Passport C70 restoration

After getting all of the little bits painted it was time to move on to reassembly.

Wiring Honda Passport C70 restoration

All of those pictures I’ve taken are really coming in handy to reroute the wiring harness.

fake cad plate

Figured out how to create a reasonable looking fake cadmium plate using spray paint, will do a step by step post at a later date.

engine kill switch

The switch gear was scrubbed clean and the taped off so the kill switch and starter button could be painted red again. All of the black buttons & switches still looked good so those were left alone.

rebuilding my C70

I had stopped at this point to do some much needed body repairs to my truck and should be getting back to it next week, so be sure to subscribe below to receive regular updates.

Clean Inside of Sockets & Wrenches

Clean Inside of Sockets & Wrenches

Here’s a quick random tech tip for you. Although this one is mainly aimed at restorers & customizers it will be of benefit to anyone who values a neat and clean appearance on their project vehicle. When it is time to reassemble your motorcycle make sure that you clean the grease out of your sockets and box end wrenches. When appearances count you really don’t want the old grease & dirt that is inside of your tools dirtying up your clean shiny fasteners. Sure on chrome plated or stainless nuts & bolts it’s more of an inconvenience having to go back and clean them but with zinc plated, cad plated or even painted hardware the dirty old crap stuck in the recesses of your tools can stain the surfaces beyond cleaning. Not to mention that grit from dirt or metal shavings can sometimes be suspended in the old grease and scratch even stainless fasteners when you tighten them down.

Clean Inside of Sockets & Wrenches

So even if all you do is just twist up a rag & stuff it through the wrench, it will make a big difference. I think in the future whenever I finish a big greasy dirty project on an engine or an off-road vehicle, I’ll try to remember to run all of the tools used through the parts washer & clean them inside & out.

How I got reminded of this…

<Honda C70 Passport Restoration>
My last big project was the resurrection of an old ATV for use as a hunting & farming vehicle. It was filthy nasty & greasy even after being washed thoroughly. When I was done all of the tools were wiped off and returned to the tool box without a second thought. Then I used them to disassemble my crusty little C70 Passport, but today when I started putting it all back together with everything cleaned & painted the grease & dirt marred a couple of the bolts so I began wiping the wrenches out after that.

Today I’d also like to apologize to my regular readers for my reduced post output over the last few months since my shoulder injury. Things are getting better now and there is a ton of material saved up, so look for a lot more good stuff to come, including some classic four wheeler tutorials, product reviews, and the return of the Website of the Month category to active status. Still with so much going on there’s no way that I can fit every cool random event into this blog so why don’t you join me on Facebook, follow along on Instagram or on Twitter. 

Don’t forget the Psyco Youtube channel!

Peace Y’all!

 

 

 

Install a Trailer Hitch

Almost Anyone Can Install a Trailer Hitch

I have a confession to make; at one time the very thought of putting a perfectly good running motorcycle on a truck or trailer was horrifying to me. But as I’ve gotten older my once hard core has become a soft chewy center. Crash damage, arthritis, and a growing disdain for any kind of suffering will do that to you. The missus & I will still do a bit of long riding from time to time, and I still scratch my head when I see a full dresser riding solo on the back of a tow vehicle. If said Goldwing or ‘Glide is surrounded on the trailer by some fine vintage machinery, choppers or hardcore sportbikes I can understand. Having discovered the joy of vintage motorcycle shows & swap meets it’s not unusual for me to take multiple motorcycles plus miscellaneous trade items, making a tow vehicle necessary. If I’m only taking one motorcycle or scooter capable of making the trip, to the show with no plans to buy or sell anything I usually just ride the darn thing because without riding what’s the point of owning a motorcycle?

<1982 C70 Passport>

One of my trailer queens.

Now let me make an apology to all of you old geezers that I used to pick on about your trailer queens. I am well on my way to becoming one of you and own a couple of motorcycles that I would never even attempt to travel on.

<Westin Trailer Hitch>

Westin trailer hitch

Let’s get on to the meat of this how to, my previous tow vehicle was a Chevy van that served me okay for a while but last year I sold it and acquired a nice low mileage 2010 Toyota Tacoma that was the plain Jane work truck of my dreams that I thought did not exist anymore. So I ordered up a Westin Receiver Hitch
hitch to fit it, along with a Reese T-connector kit for the trailer lights. Now let’s see how it was installed.

<Reese Trailer Hitch Connector>
Open up the package, and read the instructions. Then count all of the hardware supplied to make sure it matches what you are supposed to have. Next gather up all of the tools you need to match the bolts in the kit & on your truck, van, or SUV. While what is shown here is specific to my truck & hitch the vast majority of installations will be very similar to this. Buy your trailer hitch from a reputable manufacturer and read the instructions.

<hitch receiver hardware>

Don’t forget, read the instructions first!

Like most of them this Westin hitch receiver uses the bumper brackets to attach it to the truck. The instructions called for me to remove 2 of them on each side and leave one attached loosely. Work carefully and don’t allow your bumper to drop down suddenly as this could cause damage to your vehicle and or injury to you.

<bumper bolts>

 

<bumper bolts loosened>

Please make sure you take reasonable safety precautions when you are doing this. You will be handling large heavy awkward items over your head in a cramped space. It’s possible to install a hitch alone but it’s better if you have help. At the very least you need someone nearby in case it falls and beans you in the head.

<install a trailer hitch>
My truck also had the above tapped holes in the frame that were put there for the location of a trailer hitch, make sure that if your vehicle has additional holes like this that your hitch will use, that the holes are clean and the threads are good before putting the hitch in place.

<a good floor jack>
Since I was working alone a floor jack was called into action to support the receiver as it was lifted into place. For most of us a good floor jack is a necessity to install one of these alone.

install a trailer hitch
Line up the bolt holes and start all of the bolts. Do not tighten any of them until you have them all started securely. Once you have every bolt started in its own hole, then you may need to install some shims if supplied and realign your bumper so that it looks right.

use shims as needed

use shims as instructed

After the shims are in place and the bolts are all snug, check your bumper alignment again and adjust if needed.

torque wrench install a trailer hitch
Now it’s time for the final tightening of the bolts, grab your trusty torque wrench and tighten all of the bolts to the specified torque for your application.

<reese t connector toyota tacoma>
Now it’s time to move on to the wiring connections, Old timers will remember the bad old days when hooking up a trailer lighting harness meant cutting and splicing wires. Then came the Scotchlock connectors that made the job quicker but weakened any wire they were attached to and made it more likely that the wire would fail a few years down the road. Now everything is plug and play for most vehicles.

<reese t connector toyota tacoma>
The instructions called for me to remove the right rear tail light so I did.

tee connector install a trailer hitch
Then plug the Reese T-connector wiring harness in between the trucks harness and the tail light.

trailer lighting control box
The only part of the installation that required any drilling was to mount the control box. Be sure to paint the metal inside the hole and let it dry mounting the box with screws & lock nuts. Please note on some applications these boxes can be mounted directly to the receiver hitch without any modifications. One other thing to note, many modern trucks have composite plastic beds that do not conduct electricity well, so make sure that you attach the ground wire to a metal component that is attached to the chassis. Using outdoor rated UV resistant cable ties secure the wiring neatly allowing just enough slack at the end to work with all of your trailers but without dragging the ground.

Toyota Install a trailer hitch Westin
Now slide in your hitch and hook up your trailer & test everything. I have been using this Westin Receiver Hitch
for a year now dragging trailers all over the eastern United State and have absolutely no complaints about it. It was easy to install to. Even if you still don’t feel up to doing it yourself at least now you know what it takes to install a trailer hitch. See you on the road!
Peace Y’all

1981Suzuki TS185 Finished!

Well, I got it finished! The entire build is chronicled from start to finish in the 23 minute video. I started out with a little bit of step by step video, but quickly realized that with the time constraints, that would not be possible so I morphed it into an overview video. The last few minutes is me taking it out of the yard and down the road for it’s first test ride.

It ran and handled fairly well, but the stock suspension is too light for a big guy like me to do any serious off-roading with it. I just have a couple more little things to tweak, and then if I can’t find  reasonably priced suspension upgrades, I’ll probably put it up for sale after I return from the VJMC National Rally.

 

The 20 Foot TS185 Restoration Part 4!

Mission Main Street Grants

Hello everyone & welcome back! It’s time for just a few more pictures of this little project TS185 I’ve been working on but first let me talk to you a little about the banner ad above. I have applied for one of these grants and I only have until June the 19th 2015 to reach the required number of votes. If you have a couple of minutes of time & a Facebook account could you please go vote for me? It would be greatly appreciated.

 

<bmx platform pedals on a motorcycle>

As mentioned last time this motorcycle is more of a restomod than a proper TS185 restoration and one of the things that I have always wanted to try out was putting a set of BMX bicycle platform pedals on a motorcycle. So out came the reciprocating saw some scrap metal & the welder.

As I mentioned the last time I was changing the color so here it is just a plain old machinery gray from a Duplicolor spray can.

<suzuki TS185 headlight & fender>

Added the shop logo to the number plates

<motopsyco.com>
Of course there were some new parts installed, missing bolts replaced & a few leaks stopped while I was at it.

<ts185 restoration>

Some hard lessons were learned such as don’t install the clutch release arm upside down and that cheap enamel clear really doesn’t spray well in 100 degree temperatures. There are still a few odds & ends that need doing but it is mostly done. Now I just need the upholstery shop to have my seat ready this week!  I also think the new pedals are fantastic looking but I do have to be careful when using the kick starter.

<motorcycle with bmx pedals>

One advantage to doing all of this was having time to sort out the various electrical bodges that previous owners had inflicted on this poor machine. It now has a fully functional key switch, brake & taillights, a battery, fuse etc. Of course it still starts easily & runs like a top!

<1981 TS185 restomod>

Peace Y’all

 

The 20 Foot Restoration Part 3

Mission Main Street Grants
<1981 Suzuki TS185 roller>

This old motorcycle is finally making it’s way back into one piece. It has new tires, wheel bearings, brake shoes, tapered roller steering head bearings, and anything else it needed to make it safe & reliable. Surprisingly enough even after 34 years of being beaten like a government mule, the engine & transmission are still in very good functional condition. This makes my life a lot easier.

Lets start with a quick look at the rear wheel & brake linkage before I started.

<TS185 rear wheel before>

<ts185 brake pedal before>

Yes I know I need my head examined for riding it for so long in this condition, but it was still a lot of fun!

<TS185 rear wheel after>

I had to replace the brake rod, adjuster and the lever. The rod & its hardware are new old stock parts, & the lever was simply adapted from a junked motorcycle.

<TS185 brake lever after>

This is the exact same brake pedal that is shown in the picture above. I straightened it with a torch, hammer & anvil, before cutting the end off of an old dirtbike footpeg and welding it to the brake lever.

<1981 ts185 carburetor>

I had to buy an entire extra used carburetor to get a couple of parts that are no longer available separately, and I’m still waiting on my throttle cable to arrive from England so for now the carb is just sitting here until I receive the cable.

While waiting on some other parts it was time to start some body work.

<motorcycle repainting>

Have I mentioned anywhere in this series just how incredibly nasty this thing was? Check out the red clay mud dried to the bottom of this tank.

<bottom of ts185 tank>

The side covers are decent used parts that only required minor work to repair, but the tank itself is actually requiring a fair amount of body work to make look good.

<20 foot restoration TS185>

It’s so tempting just to throw money at a project like this, and to a certain extent I have done that with the mechanical & safety bits. Since this is the 2o Foot Restoration the appearance of the machine will be handled in the most economical way possible, with a few cans of Duplicolor spray enamel. So many of the parts needed for this bike are either unavailable or priced beyond what I feel like spending on it, this is actually going to be a resto-mod more than a restoration. Plus the blue has to go, I want a tougher more subdued look for my trail bike so the color will be changed. No I’m not going to tell you yet, keep checking back (or just scroll down & subscribe) o see what it winds up looking like!

<ts185 right side primer bondo>

Peace Y’all

 

 

The 20 Foot Restoration Part Two

When I posted this morning this was the picture of my stopping point last night.

The engine was still sitting on the bench looking like this.

<nasty filthy engine>

and most of the small parts hadn’t been touched yet & most of them had a thick coating of baked on red clay mud. But with the aid of my beautiful assistant I was able to get it back together this far.

<my fantastic old lady>

<ts185 frame & engine>

It’s been a long time since I have pulled a hard weekend thrash on any vehicle like this, the fact that I didn’t have to push so hard was part of the challenge for me. When I was younger I spent may a weekend or late night wrenching non stop just to be able to get back to work on Monday, and it’s really nice not to be in that situation any more. It’s also nice to know that I can still pull it off if I have to.

<ts185 20 foot restoration>

So far so good, now of to order the rest of the parts that I didn’t anticipate needing! Appearance wise this might be a 20 foot restoration but all of the mechanical bits will be in 100% working order!