Doing some work on a VFR400R

Hello Barfers, I'm doing some work on my Honda VFR400R NC30.

Here's the plan;

1. Swap the OEM stator and flywheel with one from a 2008 GSXR1000. I have a special kit with a new cover to make it work. The GSXR stator is lighter then the Honda OEM. Here's some more info http://mngforce.typepad.com/nc450vdev/part-evolution-generator.html

2. I had some Chinese aftermarket fairings on there and the fit wasn't that great, so I have some OEM tail fairings and a higher quality Tyga two piece fiber glass set for the front. They need to be painted and OEM style decals applied.

3. I can smell some coolant after the bikes been running. I thought it might be the lower radiator leaking so I took it off and checked it for leaks but none where found. I've put it back on and flushed the cooling system. There's no coolant in there right now.

4. I have a 17" RVF400 wheel that I need to get painted white then I'll swap out the 18" rear that's limiting my tire choices.

5. After the above gets done, I'm swapping out the front end for some ZX400R forks that have been reworked by Maxton in the UK (they've prepped some 400cc V4 Honda's for the Isle of Man TT). I have some trick custom triples and some spacers for the front wheel to make it work. I still need a ZX400R front fender, clip ons, 310mm discs, and maybe calipers (I have some that might fit)

Forgive the pics. My iPhone can't seem to transfer them to my Mac without flipping some of them upside down.

First I'd like to get the fly wheel off and do the stator swap. I was planing on getting a strap wrench and unbolting the flywheel. My Haynes manual says I need a special removal tool to pull the flywheel but I don't have one, so any suggestions would help. Also I need to seal the new stator cover and I've never done that either.

I figure I could get some guidance here so I don't @#$% anything up I'll also be posting this up on 400greybike.com also(link to follow)

I could have sworn I had a flywheel puller, but now I can't find it. It may not be the right size for the '30 anyway, but that's annoying.

When I did pull the flywheel off my old bike, that was one of these times where you can go through hours of pain trying to improvise something, or get it done in 5 minutes with the right tool. I'd highly suggest that if you can't find one to borrow, just bite the bullet and get the correct tool.

^Well I went and talked to Jim Granger for the first time. He does a lot of work on RC30's, NC30's and NC35's and he's local. Very cool guy. I'm just going to trailer it down to his shop and he'll lend me the puller. I did some research and there doesn't seem to be a good alternative to removing the flywheel without it. So rather than screw up the engine, I'll do it the right way.

He has some serious moto porn. Nice shiny Cosworth pistons for a NC30/35. I would love to have those in my bike!

Nice dude.. I'd like to see some finished photo's.

I used a spark plug hole chaser to pull a flywheel on my EX500; worked like a charm.

I'll take the pics upside down next time so they show right side up.. Stupid iPhone

OK just got off the flywheel bolt. Damn! That was hard, had to make my own tool out of a 2x4, two drill bits and part of a bed frame. Now to find a puller. I'll probably just trailer it over to Reseda since my puller kit won't work.

Contact info for Granger?

Crom said:

^Well I went and talked to Jim Granger for the first time. He does a lot of work on RC30's, NC30's and NC35's and he's local. Very cool guy. I'm just going to trailer it down to his shop and he'll lend me the puller. I did some research and there doesn't seem to be a good alternative to removing the flywheel without it. So rather than screw up the engine, I'll do it the right way.

He has some serious moto porn. Nice shiny Cosworth pistons for a NC30/35. I would love to have those in my bike!

Click to expand...

Is this guy in Reseda? I'm also in the SFV so he'd be much closer than any other grey market Honda guys. Can you pass along info?
Thanks!

Crom said:

^Well I went and talked to Jim Granger for the first time. He does a lot of work on RC30's, NC30's and NC35's and he's local. Very cool guy.

Click to expand...

Jim is a cool guy and fun to hang out with... his RC30 work is impeccable...

Complete picture show here...
http://bayarearidersforum.com/forums/showthread.php?t=324794

That piston he's pretending to hammer into a cylinder is way cool!

the flywheel puller is available from honda. Its like $15 if i remember right.

if you need your radiators worked over, Fontana Radiator Works does an awesome job with them for pretty cheap.

also, since you're going to the 17" rear wheel, put a RVF400 pull-rod (dog bone link) in to get your ride height back.

Alternatively, you can weld up the existing one and redrill it so the center of the holes is shortened by 5mm (difference in rod lengths). If you're going to track it, so another 2mm shorter.

Busy Little Shop said:

Jim is a cool guy and fun to hang out with... his RC30 work is impeccable...

Click to expand...

Damnit Larry! You're supposed to use the peen end of the hammer! Whadda think all those divots in the piston are for?

Yep I got a flywheel puller from Honda and finished it up. Haven't put on the RVF wheel but did get some nice Dymags that I fitted. I also installed Rick Oliver's chain spacer kit that moved the chain over 5mm to make room for the wider wheel. Then I took off the swing arm, drilled and tapped 4 new holes for the chain guide to move that over 5mm as well. The rear is already jacked up pretty high compared to a standard NC30. It has a Penske shock with adjustable ride height but I do have a spare RVF400 linkage sitting here. I also picked a Yamato Spec A twin stack exhaust a couple years ago that I finally installed.

Now I just have to get the fan to work. It works but doesn't turn on despite there being a new fan switch and wiring harness. I need that fan with all the traffic and stop lights we got down here. Hopefully my trusty Haynes manual will have the answer.

The engine noticeably spins up faster with the lighter flywheel but bogs down easier when taking off from a stand still. Go figure. Got a nice modern stator that should last for years.

Cool pic of that NR750 piston btw.