Shug Tech » Feature

1999 Honda Hornet 600cc Rebuild

shuggyboy — Mon, 01 Mar 2010 14:06:02 +0000

I bought a “basket case” 1999 Honda Hornet 600 model, The engine was blown according to the last owner.

Check out the Updated Pictures

Update 2
Update 3
Update 4
Update 5

I stripped the head off and found 6 of the inlet valves were seized open, I found a 2nd hand cylinder hear on eBay for £50!! so I’m just waiting on the head gasket, that was another £50! The cylinder head just arrived tonight so im going to strip it to make sure it is ok.

hopefully rebuild it possibly using some of the shims from the old head to set the clearances, I have already cleaned the pistons and they look to be in pretty good shape, anyway, here are some pics, I hope to keep you updated as i go along, im planning to powder coat the wheels ans possibly the frame etc, I was thinking of gold wheels and blue tank etc, but im wouldn’t mind some suggestions for colour choices!

Update 2

that’s the wheels, footpeg brackets all the odds & sods away for powder coating,

I have refitted the engine to try it, and it sounds good, i have painted a few bits and tidied up others, its getting there, heres some pics of the bike now.

Update 3

I just received a load of parts from the powder coater toady, they look the biz, check it out, the colour is titanium metallic, with a clear coat of lacquer with sparkle through it….

Update 4

got a bit done today,,, should be ready to fire up tomorrow…

Update 5

Well, I tried what you were saying and used some 800 then some 1200 wet and dry to clean up the pipes then polished with some auto sol, its just about finished, just a few wee snagging jobs left, like fitting a new speedo cable, I had a quick shot today and it felt superb,,, going like the clappers….. only problem is though that the oil light is coming on when the engine is idling!!!! im going to have to have a look at the oil pump i think?
anyway here are some more pics….

Hope you like it… feel free to leave your thoughts?

1998 Kawasaki KX 250

Marty — Mon, 10 Aug 2009 15:40:19 +0000

Another Bike hits the shed with shug going all out to build this monster from the ground up,

including new power coated frame, take a look through the pictures below, as always feel free to leave your feedback.

Something Else to Read?

1997 Honda CR80 Re-Build Part 2

Marty — Thu, 02 Apr 2009 22:12:06 +0000

Well after a few weeks of intense labor and great team work (well done shug) the CR80 is (nearly)re-born..

A few weeks ago when a box of bits which resembled a cr80 (part1) was dropped of to the shed, in what I thought was going to be a struggle to get it looking, the way it should be after seeing the crap that was in some of the boxes, but shug worked his magic once more and has re-built this bike and restored it back to it former glory, well except this small list of bits which are still in need of attention

Seat cover(didn’t have the staple gun for this post),

front caliper

exhaust can mount (paddy did a great job of the other front section brackets)

Once these parts are looked at and finished the bike will be ready for sale…also a better look at it in more detail in a future post…

Have a look at some of the pictures below…
feel free to leave your comments…

Shugtech go to Clydebank with the Quads

Marty — Tue, 24 Feb 2009 00:47:07 +0000

We had a trailer, in fact we ended up with 2 trailers.. We had our ride, a few minor adjustments to each quad, make sure all was well; especially with my 150 import, Shug re-done the valves, carb strip down, new exhaust port drilled and fixed, it was the test day for me, this day would either make me burn it or keep it..

Sunday 23rd February 2009

We loaded up the trailer with Paddys KLF 300 in front with the rest of the quads and Shug’s pit bike on at the end and well secured using a massive pulley clamp we were sorted.

We headed up to World of Golf in Clydebank, this is were we would meet Dougall riding one of Shugs
resent projects the Ram 100 quad in the car park at the rear of the driving range(just next to the five-a-side)

Once we had the bike/quads of the trailer we got kitted up and ready to roll, the paths around the back of the driving range offer the chance to get the quad opened up but not much, with hundreds of twists and turns along various paths through tree runs down gravel paths and up steep hills, once you get to the top of the hills just by the large radio tower thingy theres a small gravel football pitch, this is great if you want to race the corners or try some various wheelie action,

if you follow the paths away down to the bottom keeping to the driving range fence line you’ll come to a small burn crossing, well paddy thought it was small charging the KLF 300 through the muddy pit, but”!” the 300 dosnt have 4×4 so it ended up with us getting the toe rope out and dragging the beast from the muddy depths..

Once across & continue up and over the small incline keeping to the fence still, this is were you can get the quads head kicked in, booting it up this very long grassy/muddy path gets the dirt flying and tests out the suspension, I know cause i was thrown about like a used scud-mag, right up to the point were the main road is in view and you start to slow down for the tight muddy right turn at the bottom taking you right up onto another track, follow this all the way up and you’ll find a small 1/2 shape hut or (drinking den) that looks back down over the small valley and what a view it was on Sunday, with the sun just above the horizon making it a brilliant day for quadding…

My only wish was to get more pictures, but everyone was having such a magic time we just couldn’t be arsed.

oh and also for young Marty W to get something that lasts and dosnt brake with excessive force or use!

Martys Custom Ram

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Frankenstein 8hp Honda GX240 Homemade Gokart Test Run

Marty — Mon, 10 Nov 2008 12:23:42 +0000

Well after a few weeks, lots and lots of work done, the Off-road buggy/go-kart, is ready for the test run’s to begin, after waiting a while for the brake line to come, to get the back brakes working, to at least a stage were i though it would be ok

How does it look now

video after the break…

First day Test run Video…

Feel free to leave your Comments

Stage 1

Stage 2

Suzuki Bandit GSF400 Burnout in the Shed

Marty — Wed, 22 Oct 2008 23:13:04 +0000

This was just after getting paddy’s new Suzuki bandit GSF400 started up and running so i thought id break it in a little to get it going…

Hope you like it

Honda GX240 8hp homemade offroad gokart

shuggyboy — Wed, 22 Oct 2008 22:26:39 +0000

Well heres the start of it, rescued from the local scrap-heap, this rolling chassis was laying there and i felt bad about just walking past it, I knew the first time i seen it it could be something, but after pondering for a while I drove off thinking what a waste, it wasn’t until later that afternoon when the guys showed up, we talked about it and decided f**k it, and drove all the way back and shoehorned it into the back of the car….

After the thing was unloaded back at the shed, young Marty showed up and mentioned he had an old (when i say old i mean, laying in the back garden under a pile of shite for 3 years old i mean old) Honda GX240 generator that had the engine but was battered about a bit, we thought its worth a look, but we were just dying to see how it would look with some kind of engine on the back, after close inspection of this piece of watery crap, we says again, f**k it and took it back to the shed, I wish that we took photos or a video when I ripped the engine apart to see what kind of mess it was in, the spark plug was missing so this as you could imagine after being left out in the elements for years was just a gaping hole for the water to get in, and by f**k it got in… the barrel and the outlet ports were full of rusty muck, we managed to strip it down and get it all working, the internals were fine once it was all cleaned up…

After the re-build, we fired some fresh petrol into the carb, and believe it or not it started on the first pull, and pured away nicely! superb, I now had a fully working 8hp beast of an engine to graft onto old Frankenstein. That got me onto thinking about stopping the beast, so I fitted a brake disk from the rear wheel of a Kawasaki Zephyr 550 onto the rear axle! worked a treat, just need to mount the caliper, run a brake hose and fit the master cylinder onto the front of old Frankie.

A few weeks and it should be tearing up the grass!

The images below is basically step in the process of how this crazy pile of metal will be transformed from a pile of metal and a few wheels to a lean mean drifting machine…

Ill keep you updated with a few piccys as I proceed.

Ford Focus in car pc

Marty — Thu, 07 Aug 2008 20:57:37 +0000

Update: This was the finished unit, the fascia was finished with silver and the cd loading system was changed to a slot loader with the mold of the fascia just smooth enough for a great finish.

big thanks to “stevieg” and his site – www.stevieg.org/carpc/install/tours/ for the inspiration and ideas, and the the roadrunner team, and every one else in the scene, this forum has kept me up for hours, scouring over the info,,, its been a BIG help!!,,,, anyway,,, after many hours of hard work, sweat and vodka!!!!,,,, this is the stage i am at now.

I have a 7″ lilliput touchscreen upfront, i have modified the facia to take the screen, and moved the hazard light switch, and mounted a usb connector in the facia also.

video after the break.

I am running a pentium3 933 with 512mb ram, 60gig 2.5″ hd, 8x laptop dvd mounted in the facia under the screen. mx440 graphics, wintv for radio and television (thinking of upgrading to DAB?) wireless network card.

Its in the car now,,, although i still have a bit of tidying up to do and few things still to rigup,,, Its magic…..!!!! lol, I have mounted the pc onto a piece of plywood in the boot and covered it in material.

Still got to add more images after i locate them,,, the car pc was moved a newer ford focus, after the white one went, but since then the car pc with all its gps, tv, multimedia brilliance was gone, sold it all in bits through ebay, maybe another day, another car.

Shug Tech » Feature

1999 Honda Hornet 600cc Rebuild

Check out the Updated Pictures

Update 2

Update 3

Update 4

Update 5

Related Posts

1998 Kawasaki KX 250

Something Else to Read?

1997 Honda CR80 Re-Build Part 2

Related Posts

Shugtech go to Clydebank with the Quads

Martys Custom Ram

Related Posts

Frankenstein 8hp Honda GX240 Homemade Gokart Test Run

Stage 1

Stage 2

Related Posts

Suzuki Bandit GSF400 Burnout in the Shed

Related Posts

Honda GX240 8hp homemade offroad gokart

Related Posts

Ford Focus in car pc

Something Else to Read?