Honda CB400SS Project Part two

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AndyKK
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Honda CB400SS Project Part two

Post by AndyKK »

Honda CB400SS Project

Part two


Rebuilding the bike

Returning from our shortened trip due to Covid19

We happened to be on a road trip, starting out from our apartment at Chber Ampov, Phnom Penh. We would first be visiting my partner’s family in Kampong Cham. Over the years I have been here, I have travelled most routes from Phnom Penh to Kampong Cham, most common would be via Highway 6 then 7 after Skun. But now living over the old Monavong bridge I am situated near Highway 1, so no need to really ride alongside the chaotic traffic of the city. I have ridden via the yellow suspension bridge (Tsubasa Bridge) at Neak Loeung then heading on Highway 11 via Prey Veng. These days I would head towards Lvea Aem via the ferry too the opposite bank of the Mekong River. Heading that direction there are many possible routes towards Highway 8, and again from there onwards. I personally enjoy the 22km dirt road from Lvea Aem to Kor Kor. Then take Highway 8 to Prey Sla Road 314, the start here is a dry dusty and sparce landscape, but later following the bank of the river has the most lush and amazing countryside. At Kaoh Soutin and the Chi He Market area you can take the second ferry of the day; this one goes to Koh Pen with Kampong Cham just beyond.

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11 Mar 2020 tourists traveling by boat were diagnosed with Covid19, they were put into isolation by the authorities.
https://www.dailymail.co.uk/news/articl ... -boat.html
I decided to move on after a few days because the situation had not calmed. We ended up in Kampong Thom, and on arrival it was difficult to get accepted for accommodations of hotels, and even places to eat.
Once the people got word of this incident of coved19 it became more apparent that they wanted to blame someone for the outbreak, unfortunately for me, it was western people involved for the spread of the illness. There was a constant daily rerunning of the news story on TV. Obviously with me telling this story we had found a comfortably guesthouse, and I was going out daily to see the area of stone carvings. This was great for me; and actually, for my partner Nak too, because the stone carver’s wife had a small tented store on site. Nak could sit in the shade, eat drink and chat with ease. I love anything creative so spent my time studying and photographing the skills of the carver.

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For a few days more we would visit, it was a scenic and tranquil place to relax away from the covid19 news. But unfortunately, it wasn’t too last, due to the owner’s sister back at the guesthouse accusing me of trying to leave without paying, she wanted to call the police, I told her I had paid reception in the evening for two more nights in advance, and how was I leaving without our bags. Time, to start riding back home to the apartment.
This is really when the work started from the idea, the motivation was certainly not lacking at this time, because now I was mainly housebound, by part, and with the choice at this stage, mostly of self-isolation, only going outside when there was mainly a need to do so, such has the banking and supermarket shopping, food panda has also helped us being more confined at home, although we have had a ride out to test the bike. I have combined this with the possible visit with friends or getting parts or help with work on the machine.
So why did I do it? It was just something to do, keeping the mind occupied and the body in motion. I have the space in the apartment, but I do lack the tools, also I have stated in the past I am no machinic, but now too is an ideal time to learn.
I started the project giving the bike a good wash outside the apartment, it’s not a bad thing to do, because doing so, it’s possible to be closely inspecting the bike to see if everything is in place and nothing is missing nor loose. Once back inside I started to remove the single carburettor, I would strip it down to inspect it, clean and rebuild it. Regards to anything I didn’t know, or getting stuck with the project I was hoping the answers would be via the help of Google. Obtaining replacement parts may prove more difficult with what maybe the lack of postal services, mostly again down to the pandemic, but it’s fair to say Cambodian post is not on par with the UK’s Royal mail. It's amazing, actually what a person may be able to accomplish with very little, has at times this maybe visual daily in Cambodia, but with having the correct tools for the job, work efforts and effectiveness are made easier.

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Carburettor, 1xmotorc

I striped down the carb fully inspecting the rubber seals, cleaning the jets and their seats, and residue build up, rebuilt after inspection and a good clean throughout with clean fuel.

The work now really started to happen.

It seems that from just an inspection and a little clean up, the new but had started. But I was still saying to myself “I don’t like touching those mechanical bits and bobs”. It was more a fact that I could manage to maintain my bikes, such as adjustment’s, oil change and brake pads, chain and sprockets, cables and bulb change, tyre wear and so on. These we’re the normal things of maintenance and also too keeping myself safe on the road. But when it came down to some mechanical jobs, it certainly was not me! I had a tendency to be a little heavy handed, mostly overtightening things until you would firstly hear a crack, secondly followed possibly by some language, such like “bloody stupid idiot”, knowing that it seems now, it would have been better to take it to a real mechanic in the first place. But in those past days, you had to do it yourself, because more to the point at that time, we could not afford to have a mechanic do the work for us. When starting out with motorcycles myself and most of my friends could just afford the bikes, but the upkeep was a labour to learn, with the hopes that nothing would ever go seriously wrong.
Year’s, ago I had a Suzuki GT250, after getting a rebore to the cylinders I bought new pistons and rings, also I got new bearings for the crank, what could go wrong? Firstly, I parted the engine casings to fit the bearings.
That part of the job went very smoothly and trouble free, but it seemed to all go wrong putting it all back together! When tightening the bolts on the engine I split the engine from one side to the other. Araldite was the best, and easiest quick fix at the time, but my problems seemed like they had just started because, then putting in the new piston’s, I snaped one of the oil rings. I then had to go and buy a full new set of rings, yes, not just one ring to replace the broken one, but the full set of four, because that is how they were sold.
It was not just an expensive learning curve in those days, because like many we could not pay for someone to do the repairs, we had to do the work ourselves, that was purely because of being young and having a lack of funds.
Later in my biking years my Kawasaki KR 250 needed a slight tweak on the power valves, my son helped me at the time get the engine out of the bike, he was very careful with machines, but he had learnt for some time first hand by working in a local garage when he finished his schooling years. We handled the engine to the workbench, this sounds like a big job, but it was only really to check that all was well with the power valves. I had two final race meetings to complete that season with this 1989 Japanese KR hybrid, it was hell of a machine, I have had a fair few 2-stroke bikes before this pocket rocket, and nothing else compared or came on par. Apart from another bike I had at the time invested in.
It was one of my friends who happened to introduce me to the road racing scene who let me know about the bike, and also that it would be at the next weekend’s race meeting at Liverpool. He knew did my friend, how much I enjoyed 2 stroke machines.
I viewed the bike at that very meeting, a Yamaha TZ250H. I had a quick look over it, and had chance to have a ride to test it out. I wasn’t disappointed. I bought the bike from the two race guys who had plans together for racing it, but for one reason or another never got around to doing so, it was more likely that they were racing in the super sport class at the time.
Anyone who racers a motorcycle or follows the sport will have heard of, or even seen their bikes watching televised races, such has the road races or British super/sport class. Padgett’s, they happened to be the main importers of Japanese race bikes, such has the TZ, and at the time their bike showrooms were just down the road from me. I wrote down what numbers and kept the paperwork I happened to have from the sale. One visiting the shop it didn’t take them long to tell me a little history (it was the Astro-light wheels that gave the first recognition) it turned out the machine I had just invested in, had finished fifth place in its class at the Isle of Man TT. That bike was to be the next serious project for me, unfortunately not to happen because of unseen life events.
The 1981 "H" represented the factory's first departure from the popular 54mm bore x 54mm stroke (essentially) configuration of the previous 9 years along with a switch to an individual cylinder casting configuration. In an effort to further boost horsepower, the bore was increased to 56mm and stroke reduced to 50.7mm, achieving the full 249cc in the process and mechanical exhaust power valves were fitted, as was a transmission oil pump to deliver the reduced oil capacity of the gearbox to crucial points. The "H" had a 38mm shorter motor than the "G" and 36mm ZC series Mikuni carbs replaced the usual 34mm SC's, which had been in use on the 250's since the TD3 way back in 1972. Intake port was again widened, as were the secondary transfers for the second year running.
The motor spun in reverse direction as the factory tried to further reduce the stress on the rear of the pistons. The crank was no longer a single unit, it was now a pair of cranks with a gear on the end to deliver the power to the gearbox. Despite the frame shedding 3kg, the overall weight was reduced by just 1kg. The steering rake was altered and the swingarm also lengthened to compensate for the shorter frame length of this model. The engine was now mounted slightly further towards the front of the bike. The new rear shock became fully adjustable for both compression and rebound damping as well as pre-load and the shock picked up a rear rubber mounting. The fork diameter went up by 1mm and brake wise the factory reverted back to the old cast iron callipers which didn't bend under pressure and also didn't fade when hot. The new ignition dropped an igniter and pulser coil, there was now just one of each and the inner clutch hub now became a single piece unit to eliminate one reliability problem from previous years. The un-necessary neutral switch mounting disappeared
So, the KR lump was sat there on the bench, my son was straight at it, gently feeling that all was in place and nothing amiss. He said to me this rod feels like there’s a little play, I think it may have been a 6mm spanner, gently does it was the feeling, we both had our heads down looking closely at the part, shortly our eyes met has we lifted our heads together. “Dad” there was a bit of a delay before the next few words. “Dad, you’ve broken it”. I knew I should have let my son do the adjustment, not me, why the hell did I do it, even to this day, I know I should not have gone near that engine with any tools whatsoever.
That one snap of the small metal rod taught me a lesson to take a little bit more care, possibly being also gentler and feeling the adjustment more, in the future, or simply to leave things alone, also that of my carelessness costs me £250 to put right.
Later years, there was only that of the basic road going maintenances I could even attempt to carry out because the bikes (such has Ducati) got even more technical and was left for the specialists of those computerised hi-tech mechanical wonder’s.
It’s funny, when you write, you also tend to have a few memory jogs too. My apologies.

Back to the project in hand

Next job would be to inspect the brakes, front (Single disc, 2-piston calliper) rear (drum). Same again, strip, inspect and rebuild, checking pad and drum wear, change fluid in the front hydraulic system. Chain and sprockets next.
Then I decided I was going to tidy up the full wiring of the bike, this came about when I wanted to check the battery. The battery that I could not find! I looked it up on the internet, I could not find a wiring diagram nor that of a battery or its location. But the parts finder does list the replacement part and number, so where is it? Tank and side panels off, airbox and filter off, headlight in bits. Reposition wiring and cables (use of tie wraps and electrical tape) clean fuses and reposition of fuse boxes, mystery missing battery found, lithium battery, just a little larger than two AA size batteries, this being something new to me about using such batteries has an alternative from the original. I also made better fixings on both side panels, plastics of such seem to lose the brackets and fittings over time.

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The battery behind the panel

Choice of end cans.

I bought another end-can and fit it too the down pipes with a little modification, bought originally for the Honda 125 MSX.

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I soon decided not to go with this option due to burning myself! I pulled up outside, what I call my local vinyl shop, getting off the bike I caught my right calf against the exhaust “ouch” that hurt like hell, the shop was full of young men, and all eyes naturally were on the arriving Barang whom was crazy to just catch his leg on the bikes exhaust when dismounting from parking outside the shop doorway. I bit my tongue, without any sound or notion of what just took place I preceded to walk into the shop, the guys in the shop doorway parted quickly to the left and right giving me clear passage. I bought my sheet of vinyl and left very casually.
They didn’t have the lettering I was looking for, but no worries a new shop opened lately, and only a few hundred yards down the road in the direction of home. I pulled up outside the shop just off of the road, the banking is a little short and steeper than the last shop, I was swiftly approached by the pretty young lady shop keeper asking what I needed, I pointed at the bike tank and said simply “Honda”. “Have” she replied to me. There were two more young ladies in the shop. I got off my moto to follow the lady into the shop, “oh shit” not again, and now you could smell the burning skin, thing is I could feel it more than ever, and in the same place has before, and it really hurt now, and I was wondering if the shy ladies inside had noticed or the guys putting new vinyl on their moto’s. It didn’t really make a difference, because nothing was said.
Be aware that some items that you may buy and add to the machine may not carry any regulations, like they will mostly have to meet safety standard’s back in home countries. That of a heat shield, or common sense in my case would have stopped the problem after the first event.
In the outset I had the choice of three, but reverted back to the original, with liking that one more for the style.

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Then again it changed once more to an Akrapovic end can.

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It may seem straight forwards to having the choice of end can. Too some point it was, and it was a part that is available in many of the bike parts shops in Phnom Penh. The biggest problem at the time was not the availability of the part, but that of the law’s decision on the noise regulation. At the time because of complaint, police were to stop many riders and their bikes around the area of Independence monument. It was now said that bikes over 125cc had to comply with a sound level no higher than 90db. With the baffle included and supplied with the new Akrapovic end can, I also put a baffle in the midsection of the exhaust just below the rider’s footrest, and was well within the sound level expected.
Replacement of the adjustable rear shocks.
The next thing was to get the balance, that I was seeking from the start of this project. The problem I thought was the bike was high, and more so at the front. I will say here that because of the original high styling of the bike, they make a very good conversion has a “Scrambler” that I would say would have most likely been an easier project overall.
So, the front forks would have to be sorted first, then it would be possible to align the bike and see what the size of rear shocks would be needed.
What I originally wanted to do was cut the spring down in each fork leg, and have them re-welded to the washer that sits in the bottom of the fork legs. I made enquiries at a few bike shops, and only one in the end would take on the job. I asked again what would be the process of the work. They simply would not change the fork seals, to start with, even that I specified I wanted them changed because if they are going to be disseminating the fork legs, to me it sounded reasonable, and the best time to do so. Also, they had some doubts about things, but because of the conversation my doubts were now focused on their ability, or lack of abilities. Next, he was telling me over the phone if it went wrong, he would be looking to find a pair of new fork legs! Now, alarm bells started to ring, because they aren’t touching the fork legs, “only if they changed the seals” but only the fork springs would be worked on, even so they wanted $100 for the work. I decided I did not want to chance these people with the work. It did cross my mind that they were talking the job down because they didn’t want the work.
So, what can I do now! I was wondering what I could do and who may be able to do the work, or even could I do it myself to be on the safe side. Then I thought I will take the easy route by sliding the fork legs up through the top yokes to see what adjustment Is needed. Apparently on more research of the subject, it’s about one- and three-quarter inch limit only, with the fork passed through the top yokes to do it this way.
Now I have another problem, or challenge, depending on how you’re looking at it! I would say all these modifications go hand in hand when you may decide to start a project.
But, before I can adjust the forks, only a simple problem with the handle-bars getting in the way by about one quarter of an inch, stopping me from moving up the forks. I could simply and more easily change the bars, but then again, I like the flat bars, simply for the riding position and styling I am trying to achieve, so I didn’t want to change them.

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There is only one simple answer to this problem.

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The simple solution too my mind, was to bend the handlebars, they would be bent to fit around and accommodate the raising of the forks above the top yoke with no restrictions.
Doing like so, I would not lose my personal want of the style and position of my preference of how the bars would look and feel, being also very suitable for my riding position. But, unfortunately after a little time the wrists begin to hurt, but all it takes to sort this problem is a quick shake of the hands from time to time. I would say overall it’s not a big problem, it would on the whole be a larger headache going round the bike shops trying to get replacement bars.
The second problem was having the tools for bending the handlebars, or getting someone to help me bend them, because I would not imagine an easy task alone.
It just so happens one of my Khmer friends has a Moto repair shop, and he and his step son have taken care of oil changes and a little adjustment here and there on my Honda MSX since moving to Phnom Penh. But he was positive that he was not capable of doing such work that I was asking him to do on my handlebars. He was being so adamant about this, and also, he flatly refused to do the work to the point he explained to two suited gentlemen who were having their bike tyres inflated at the time. One of the men told me in perfect English, I should leave and look for someone else to do the work because he wasn’t capable of what I was asking.
In fact, my friend, he was so against anything new to himself he would not even consider trying.
I could not believe what I was hearing, and was thinking that he has learned to do what he is doing now, but is that it, and that is enough to make money. Also, I am thinking to myself that this maybe the only chance without chasing around once again, and trying to get some kind of commitment from another person. Again, I also don’t have a scaffold pole that he had in the shop. So, I told and reassured him, that he would be helping me with the work and I was going to do it now with him has he closed the shop doors at the end of the day, so there would be no onlookers too worry about, also he had no responsibility for any mistakes made. Plus, I was going to pay him for his time regardless.
It worked out fine, and his payment was asked of me to drink a few cans of beers together. We are still friends today, but I don’t push him to do anything that he is not confident in doing anymore, but has it happened the Moto work has taken on a back burner, and his step son has gone to work for another moto shop, due to his lady’s cosmetic business doing so well, now he spends his time with a few collections and deliveries of the cosmetics in the day.

Comfort in a new Seat.

I had stripped down the seat to cut a little off the hump, being that it was a little uncomfortable for my partner riding pillion, it was also holding a little water, the sponge was old, so I had a new one made locally using the seat base, padding and cover came in at the low price of $10.

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Making the new seat.

Little parts can make a difference, if you can get them!

I have changed the levers with a smart anodised pair from Malaysia, they are the make of ROC the quality of these replacements really show, they are also the adjustable type, and they did cause me a little work to get them to fit, overall, they are precise and return you feedback, they are a nice addition.
Again, I must add from the writing above, there were one or two problems to overcome, one being the shop who sold the rear shocks would certainly not sell them to me, it’s not the usual case of Barang tax. Infact it is known he won’t sell to a foreigner full stop at any price. I have come up against this kind of none sale, unfortunately at only a few shops, and there’s few alternatives in some cases if you wanted a particular brand or make.
I was wanting to put on a pair of rear sets, but after the last episode taking a pair with other items in a shop ready to pay for my goods at the counter, but then by the shop owner being bluntly refused the sale of all items. It’s a crazy situation to find yourself in! My partner was sat on the bike outside, she said on my return “where new bike parts”. I told her he won’t sell them to me. “Crazy” she replied.
This type of none sale does tend to make things a little difficult at times, my only answer was to get a Khmer friend to buy them on my behalf without me being there in the shop, and obviously pay him/her for the time, because it’s the only way to get the item.
It’s one thing to be charged a little above the items price at a shop, the extra that to some of the sellers is expected of us, being that we are also seen to have monies in their eyes! Be it, because the western tourist on his or her short holiday can and will spend money’s with very little concerns about being over charged here and there, a little extra riel (being only penny’s) above the true price, most will pay, just to satisfy the sellers and not get into dispute to risk ruining their vacation. Being an expat and the same situation, I expect may not result in the same (oh well) attitude towards how we may be seen by some locals, such of our government may give that of our past paid tax monies in large nomination’s adding to millions of dollars in donations to that of good causes. Has well you may have given to a charitable organisation, or still do. This also portrays what western countries do, and you are one of them, who can afford. But again, living side by side with these people it’s up to the individual who may receive the extra, or will they move on to the trader whomever treat us like equals. Being refused a sale of goods is a totally different situation. I say this because it’s not always been that of an isolated one-off encounter for myself, it’s happened on several occasions with this project. But, it’s maybe that of the reason why the shop owners or their assistants won’t sell to you.
It’s best not to dwell on the situation too much, but it’s a simple fact “they don’t like you”. In the west if we compared the same situation, then the customer of the shop who comes first, because they are the ones that are buying the shops goods and keeping the shop owners in business. Although here that is not the case, the feeling here is the shop and owners have, and the customer has not, so the shop has something you need. Catch 22 situation, without you buying, you don’t have, without shop selling, they don’t have money.
Also, in the west it would be more than likely that the racist card (so to speak) would have come into play. I have since learnt that is not in question if the situation would be reversed. Apparently, a black person cannot be held to be racist against a white person, they can only be that of predigest towards the white person if they themselves are black. But then again it would make no difference too that of one’s situation, because who and where are you going to take your complaint or grievance.
The above reasons are why the goods you wish to buy, will not be sold to you, or me has the case was, and overall, not a good feeling, but there it is, so best move on, because there’s nothing can be done if you find yourself in a situation like this.

The cosmetics of the bike.

I had the bike vinyl wrapped at one point, the main reason why I did this, is because too I wanted to learn how to do this process myself. Initially it cost me around $15 to have the bike wrapped, there was no problems in watching the guys and that of the process how this was carried out. It’s all well and good watching on YouTube, but you can’t beat being there in person to experience the technique and procedures of how to wrap.
I had actually wrapped the bike myself, had to invest in a quality hairdryer at the time with numerous heat and speed settings. I recall the price of about $12, it I think a better alternative to a hot air gun, also because the hairdryer was more practical being that my partner could use it too for her own needs. The cost of vinyl per meter is approximately 5000reils, so overall a cheap way of protecting and presenting the cosmetics of a motorcycle.
I have since painted the bike about 4 time’s, again you could just say something to spend time on while we are in this pandemic situation. Then again it has been my working life profession being that of a spray painter. I said to myself I probably would not get involved with painting again, leaving that chapter of my life in the past.
I have coated so many items in my career and business being that of a painter, from various vehicles, bikes, cars and the largest of commercial transport. Buildings inside and that of their outsides too, new build projects to old grandeur establishments, dwelling housing too hospital operation theatres. But my main work had been subcontracting to the oil industry and petroleum industry, such companies being British Petroleum, Shell, Esso, Total and the rest. My work of recoating tanks on their refineries, but more so taking care of painting site works, and the main work of rebranding and spray painting the petroleum pumps of filling site’s, being the mentioned companies, working around the UK on that of a contract basis.

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Have you ever tried kidding yourself? I actually started to miss painting to be honest, funny in more than one sense, being that it is that of a long profession it has allowed and funded me also to be in the position of being here today.
But regarding the painting of the bike, it was recently suggested that I do another thread on the subject.

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Mechanically the bike is very sound, with its strip down and rebuild, new oils and fluids, adjustments and alterations, no part has been overlooked, and no expense spared. Now the bike kick’s up first time has a rule, 3 time’s if cold, being that of its first start.

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But I am overall happy with the results and over all doing this project. Now I may be looking forward to finding possibly the next project, I have one or two ideas but may need to see.
The bike is complete now, nothing more I would do here.

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Always "hope" but never "expect".
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AndyKK
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Reputation: 2248
Great Britain

Re: Honda CB400SS Project Part two

Post by AndyKK »

Mentioned before in this or another thread was the subject of luggage. I must admit it wasn't ideal, but you know if you take the young lady along with you on a trip, the baggage just increases with everything they may not kneed, and you're left wondering "where are my cameras going to go. It also may be said if I was to travel solo, one small backpack would be sufficient. I mean what do you need other than a change of clothing and a toothbrush.
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Throw-over soft panners had been mentioned, I did have a pair back in the UK. Anyway I went out and bought a new pair of rucksacks, ideal when put together over the back of the seat. But I would need to construct a small framework so the bags didn't go into the back wheel. Doing the framework, had me then thinking of my original idea of using a solid type box, being more robust and secure. I had much thought about this, thinking the best solution would be to get those guys you tend to see making the lightweight steel boxes here and there, I one bought one very cheaply for the use of a cash box for the bar back in Koh Kong.
But then again if I am going to start construction / fabricating something, why not an additional item, when needed.
So I come up with this answer, and it's something I have never attempted before, this type of metalwork.

The all terrain trailer -

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Always "hope" but never "expect".
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