Honda Pacific Coast PC800 3D printed mirrors

Here’s an option to replace broken mirrors on a Honda Pacific Coast PC800 motorcycle. Because the mirrors are no longer offered by the manufacturer, there are only a couple solutions to a damaged mirror. You can buy one off eBay or a similar site for a lot of money (as of April 2021, I’ve seen a set of mirrors sell for $500). You can contact Alex in Russia to have him resin cast new mirror plastic parts for you. Or you can contact Ruud De Greef via Facebook to buy 3D models of the PC800 mirrors and 3D print your own.

This post shows some of the info that I’ve pulled off of Facebook from Ruud De Greef. The original post is here.

I have no experience with the 3D printing files and I do not know if they are any good or not. If you buy the files from Ruud and they work well or they do not work well, please let me know so I can update this post.

Note that it appears only some of the parts are available for 3D printing so you’ll still need some parts harvested from your busted mirror.

Some people in the comments on the Facebook post mentioned that there were 3D STL files available several years back but I haven’t been able to find the files yet. I’m not sure if Ruud’s files are from the old STL files that a few have mentioned or if they’re created from scratch.

Here is something about the challenges of 3D printing old bike parts: https://www.fabbaloo.com/blog/2019/6/27/how-to-re-engineer-motorcycle-parts

Here is an old Reddit post that mentions someone at some point was 3D printing parts for the PC800. I haven’t been able to find any other information besides this: https://old.reddit.com/r/motorcycles/comments/63sup7/are_we_3d_printing_parts_of_our_bikes_in_the/dfwob04/


I have the mirrors from the PC800 transformed in a digital format. You can now print your mirrors yourself. The costs are 120 dollars for all files (see photos). IMPORTANT: you don’t get a real product ..only the files for your printer! Please send me a PM if interested. Printer volume needed: 200 x 200 x 250mm

Ruud De Greef
16 hours print, Pet-G material, 0.4 mm nozzle,, 0.15 layer height.. just out of the printer, no sanding, just removing the breakaway support structure (2 minutes of work). BASF Ultrafuse ABS Fusion+ – Ruud De Greef

Laser Exhaust for the Honda Pacific Coast PC800

A very interesting exhaust system manufactured by Laser showed up recently on a Netherlands-based website as they parted out a PC800. A PCer in The Netherlands bought the parts and has installed them on his PC. I’ve collected what information I can about this exhaust. If you know anything else about it, please get in touch with me.

Based on the photos from the parts dealer, this exhaust fits into the same location as the stock PC800 exhaust. The muffler is in the stock location (no second muffler on the opposite side).

Here is the part number on the stainless steel exhaust. It seems to say:
LASER

BSAU 193 T2
e4 89/235-890
31.1073.9

Here is a still from a short video of the exhaust system in place on the bike. You can see it bolts to the stock location. Video is below. You can hear a short clip of it revving.

The most interesting thing to me is this exhaust collector/resonator. It looks like a piece of art.

The muffler has the appropriate mounting tab to mount to the stock exhaust location on the PC.

This is a collection of photos of the two exhaust headers that sold with the rest of the exhaust parts from the PC that the parts dealer parted out. I’m not sure if these are special or different from what comes stock on a PC or if they’re the factory exhaust headers. My guess is they’re probably stock and not special.

Here is the sales literature for the exhaust. It’s from Jama Originals. Over the stock bike, the exhaust does slightly improve performance on the dyno according to this graphic.

Here is a photo of most of the parts that came out of the collection of exhaust parts that the bike breaker sold to the PCer in The Netherlands.

The OEM part numbers involved are as follows. I am not sure of the part numbers from the aftermarket company other than what’s written above.

18231MR5000 – for muffler

18320MR5003 – exhaust pipe

18392MK4000 – exhaust pipe

18320MR5003 – exhaust pipe part 2

18300MR5870 – exhaust silencer

UPDATE!

A Laser exhaust recently (July 2021) was posted for sale on a Dutch website. I grabbed a few photos of it and have added them below.

Removing and reinstalling the crankcase cover and torque specs for the clutch bolts on a Honda Pacific Coast PC800

For those replacing the clutch or the clutch springs on a Honda Pacific Coast PC800, this information may help with the procedure to remove and reinstall the left crankcase cover, and with the torque specs for the bolts that hold the clutch plates in place. This information comes courtesy of Seth on the iPCRC.


Tips: Do mark the cover to indicate where odd bolt lengths go and any extra dowels, brackets, clips, … :

There are a couple of flanges that make pulling the crankcase cover easier.
Front:

Rear:


The little bolts that hold the clutch plates and springs in place are Class 8 M6x1 20mm flanged hex head screws, rather stronger than the generic hardware. There ought to be an underlined “8” on the head:

(It’s underlined so that you don’t read it upside down and confuse it with an “8”. Braille on a drive-up ATM keypad?)

The Page 1-14 specification for “6mm flange bolt (10mm head) and nut” is “12 (1.2, 9)” (N·m (kg-m, ft-lb)). That matches the explicit specification for the clutch bolts on ‘oldWing, my 1984 GL1200A, which uses the same size bolts.

FWIW, when removing the bolts from Winglet’s 1997 clutch I tried to measure the torque required to break the bolts loose. The results, in in-lb, were: 114, 126, 120, 126 and 144+.


When re-installing the crankcase cover, apply sealant to the pulse generator wiring gasket before installing the crankcase cover gasket:

I’ve been using Permatex Optimum Black Gasket Maker instead of HondaBond lately with good results.