Resurrecting a wreck - 2016 carby Hima - is it worth it? **DIARY**

sam2019

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Winter in Rishikesh can be boring. A soon-to-be visa run and other stuff kept me from going to Goa. So I bought a wreck. I am still convinced the carby version is the best and all this EFI shit is thrown on us by fanatically left/green politicians (in India and as far as bikes go).

In this thread I will list the efforts and more importantly the moneys spent to make it into a newborn beauty. Of course this is relevant only for Indians - for the rest of the planet it is meant as entertainment (I hope a worthy one).

So let's get started:

The plus side:
  • The price: 65000 INR and that includes a brand new engine body overhaul with new cranck
  • The bike overall is in a not too bad condition - minus of course the wholly destructed engine (that happens if you lose oil and continue driving!)
  • The rear tyre is as good as new and the front one is acceptable (65%?)
  • The frame is without damage or even the slightest sign of rust
  • There are no signs of any accidents other than the occasional tipping over from the notoriously long side stand (caught by a crash guard)
  • Electrical system is fully functional

The minus side:
  • Engine needs new cylinder and head but I happen to have a new BS3 head lying around and a 500cc forged piston that will go into the newly sleeved cylinder
  • The instrument cluster light on the compass and speedo does not work - could just be a defective LED - or a new instrument (expensive) - time will tell
  • Rear mono shock is defective (just wear and tear) - expensive!
  • Front shockers need new spings
  • Front wheel needs new rim
  • Rear brake needs new disk
  • Both handle bar switch sets are worn - need replacement
  • Front light plastic housing is scratched - will be replaced by an INTERCEPTOR light because metal!
  • Gear shift pedal is worn out as well as the right side pillion footrest
  • Of course the battery is dead
  • The chain set was dead 5000km ago
  • Mandatory exchange of the t-stem bearings to German/Japanese quality
  • Mandatory exchange of the first generation swingarm (they tend to break at the monoshock attachment)
  • Mandatory exchange of the awful stock seat to our proven long-distance seat
  • Mandatory exchange of the low handlebar to something more fitting for off-road use
  • Complete paint job - probably the new all-black BS6 design - or the red/black/silver
  • Carburetor overhaul and 130 main jetting

In the west this would be a lost cause right there - the price of the parts would outweight any possible gain over a new one - but not in India. I do not have the numbers yet but will publish them as soon as I know them.

... to be continued
 

sam2019

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Disassembly going on.
Tomorrow off to reinforce the frame:
 

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sam2019

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Today the frame was reinforced and the tank as well as the mudguards went to the paint shop. They will be done in the BS6 black design (I hope)
All "special effects" where ordered thru Amazon - those I did not already have in stock.
 

sam2019

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Collected the base engine housing from the shop that widened the opening for the cylinder for the 89mm liner to fit.
tomorrow an entire suitcase of parts will go to our workshop and we will find out how far we get rebuilding from a naked frame until we have to stop because a small but essential item was not ordered and is out of stock...
 

Sasa

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@sam2019 why the case widening? Planning on going full 500/510 on this carby bike?
 

Dool

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Collected the base engine housing from the shop that widened the opening for the cylinder for the 89mm liner to fit.
tomorrow an entire suitcase of parts will go to our workshop and we will find out how far we get rebuilding from a naked frame until we have to stop because a small but essential item was not ordered and is out of stock...
which small item?
 

Dool

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What sort of gasket could hold up RE Technicians?
 

sam2019

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As mentioned the bike is a wreck. Accordingly the list of parts on order is long, very long. The order went out when I first bought it, that was 29th October. Yes, it takes that long now. What can I do. I think the restoration of a 60 year old BMW in Germany is faster than that of a 6 year old Hima in India. Some parts are essential to even start the work, and for those we wait. "Luxury" stuff like a carrier and a new front wheel we can always add later.:devilish:
 

Dool

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OEM side cover Gaskets that I have removed are a Metal sandwich and can be Gooed up and reused.

Well I have done it , here the gasket is expensive!
 

sam2019

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Slowly the ordered parts are rolling in:
 

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Sasa

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Slowly the ordered parts are rolling in:
It's coming along pretty nicely!

What about that bracket for the dash? Is that aluminum or steel?
 

sam2019

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It's coming along pretty nicely!

What about that bracket for the dash? Is that aluminum or steel?
Alu, we used to make them but they only fit BS4 so we stopped. The original design is from some guy in Latvia I think it was, but he has long stopped selling them. Laser cut, then hand bent.
 

sam2019

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So far so good, now more waiting, for parts - like the engine cover.
In this engine everything is new, including the 86mm forged piston.
 

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sam2019

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What "farkles" does the bike get:
  • Tyre hugger
  • Voltmeter
  • 12V charging point
  • Battery OFF switch
  • Elevated handle bar
  • Barkbusters
  • Long distance saddle seat
  • Conversion to "road design" (No side frames, light follows turn, no beak)
  • Special "Bullet type" crash bar
  • 2 x LED fog lights
  • Pair of car horns
  • BS6 enhanced carrier
  • OEM pannier system
  • Quality mobile holder with USB
  • Side stand platform for muddy ground
  • Special paint design "2 blacks with red stripe"
What technical enhancement does the bike get:
  • All greasing spots re-greased with German marine grease
  • Head bearing replaced by Japanese quality bearings
  • Headlight Phillips LED
  • Light OFF switch
  • Engine upgrade to 500cc
  • Oil Thermometer
What will be replaced for new parts:
  • All bearings
  • Rear mono shocker
  • front fork shockers
  • Wiring harness
  • Swingarm with connecting parts to mono shocker
  • Front wheel rim
  • Front and rear disk plates
  • Front brake caliper from BS6 with Yamaha sintered pads
  • Complete engine overhaul (new crank, connecting rod, cylinder, head) - upgrade to 500cc
  • Carburetor overhaul with bigger jets
  • Exhaust stock from BS6 (or PowerAge)
  • Paint job overall - Black
  • Side panels from BS6
List subject to updates
 
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