Resend my activation email : Register : Log in 
BCF: Bike Chat Forums


Royal Enfield Bullet 612cc project

Reply to topic
Bike Chat Forums Index -> Show & Tell Goto page Previous  1, 2, 3, 4, 5, 6, 7, 8  Next
View previous topic : View next topic  
Author Message

pepperami
Super Spammer



Joined: 17 Jan 2010
Karma :

PostPosted: 09:36 - 06 Aug 2018    Post subject: Reply with quote

Very impressed.
____________________
I am the sum total of my own existence, what went before makes me who I am now!
 Back to top
View user's profile Send private message You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 18:09 - 07 Aug 2018    Post subject: Reply with quote

Pegs/stand update. SImple really, just needed some spacers. I copied the right one off my 350 bullet then had to make the LHS one to fit with the stand.

https://lh3.googleusercontent.com/TRf_-M-iuexB_PX37jIEoFBz8XVoNc50ijSXByzr_GQNO31Nr2CpyHDZL2j6DApA128gdQGwqqFAQeFaO4F0kDPRDSK4HfbHSeQA9-biOTYsYfdwg_CpVy8zpAJ3p06Tr8rZkF3fug=w657-h876-no

https://lh3.googleusercontent.com/0sJLmEnE1niumKAAYcAfV6xmcZZM-4LiEufU7urwOx2FdiyiXKY08SU-XAXEcUESR4zVXSB46X_NByQjG0I51nrUw0cPktuF9Ifa7dA7CDidw4d96TeMFKKjrSbJoxThpIKw-L8o_A=w1168-h876-no

The choke cable was annoying the crap out of me. Cable adjuster right where I don't want it (topmost cable) blocking the hole in the nacelle. It's also entirely unecessary, there is an adjuster on the top of the carb.

https://lh3.googleusercontent.com/EZsFf9MuxZ7Qzx9IVqE4nKBNogwxGijhfTKpH4FRX7iBo579BM215LYbKicY7JQpLFztR8DtkRe8nliVt2nawBoHlyMl-pWdevldxoMb4QkptezcqL2tFKCJlVtGX4xLPVkK3-UG_w=w1168-h876-no

So I made a new one with no adjuster and of a thinner grade cable, the stuff supplied would work a brake, never mind lift a choke slide.

https://lh3.googleusercontent.com/KOkLs86EOSI3GujpaDKm1ly9VSNzeHS9hREWl7jdkBkdImA2PUNnVynkn9rGeVG2wmeut0K9v73co23uZCjN-KBNiiE7hWW7TIZyOWHkSFKXwAuiXC_X2_to-FAY-oc1WtYXcyIgWg=w1168-h876-no

My nipple soldering is improving.

https://lh3.googleusercontent.com/JRfJHUOwl6ScK2TBs7YDcesmSQgqgdmAKDq0UT9boVF8pgsQWBZc7JPLoK-rp6PAfPZb1zq-dscE1LrmfiHyzwvXBZ17RkY98L2enoULlTlB1dZEWS2bWbRGYMIQ4KJDoaU9pLhvRA=w1168-h876-no

So. Electrics. I started by sawing off the forward facing metal "spout" on one side of the tea caddy and replacing it with a 40mm stuffing gland. Th eother spout faces down and inwards so shouldn't get any serious water in.

https://lh3.googleusercontent.com/YRqr37wfIOqyTe8Kl4NGiBIXxtc9_WXcOLIO3Tv4jxQTQf6h2DxL0Uyu2mQrHM3BriYWdeCfdDwH7kmJzMQ8YtLZDQScIMgaBatj-mNa7A9xJm3rLbzPA97CyLu-ZplxD_FR8E1Bmw=w1168-h876-no

Automatic wire strippers really speed this job up. I'm using non insulated crimps so the correct crimping die is essential.

https://lh3.googleusercontent.com/LPadKNiRRP0gUz_n4IF9tcuBRGYB3eXcUubKxXKcFX8IG9yZm58uheTuP_DvbV0Z9jHvfHP88GQqQv2hbBCD3-v3xc03UF0DngfUNUtnihgfubplh7iAaf_JSg-3hJ8bcGBi4_LGTA=w1168-h876-no

To prevent corrosion, I'll be applying this dielectric silicone grease to pretty much everything.

https://lh3.googleusercontent.com/BZN_ahfABi6m4s_vLPCp6YvttW0PnsKdpxpuLG1icySuQFJXS8uTzAzFlkmjcqBh74opHmTsZAvSvb1QnGh3W-VeCThgje1G6HSr1-1OoOCigCBGYoYKjXboNTPjPRkHMBIlcNJQCw=w1168-h876-no

Here's what most of my connections will look like when complete. (ignore the ones inthe background, they were from my lash-up loom)

https://lh3.googleusercontent.com/6l45Uufwd1QU1kjSMr9Znaw-f1VHoz_8O_PVhYrRJsKwM5iaX9HFZADnL82N2KHCaZJdN8R4LqyotjnetuiuloffKsFs0lWo3oU2iCV_6-MMXKFHHKxz0YQsDLv5VOCNn-gJkZoJOA=w1168-h876-no

Main earth point. I'm doing earths seperately to the rest of the loom. They will all loop to at least one earth point AND to one another, effectively making redundant connections.

https://lh3.googleusercontent.com/8y-sGSaTbE6mIj0G-n9swGhriwu9hroJcCWcptpZh-sRrAeFrk-9bmRFdBKYdisejRJxDgavnKKRZMevonYdfu3Vyp4WfXv9UV5gePrzxEqDPm6EzTYymlVSNV_7yM4oGZ_EaY3m5A=w1168-h876-no

The big earth rings only have one crimp point so I've soldered them and aplied silicone insulation tube.

https://lh3.googleusercontent.com/9crUts03Rc4yFRtfddEuzIkJWbaKooPUoCxVbFf7bfxU2F5g3C38uhkvgBP7BdXRZ7ZkUB29UTYWY-O68inOfywbVzA9CXX8XjshyIfs52_wUlM2UPklKKASG0ivRTrsFcwUQlz_sw=w1168-h876-no

https://lh3.googleusercontent.com/QHAP3onqHybOjhbUPwD8hNjU0Wjj_FqWays3pABmwhAs3gojcpNHyLBbkHQRONrkzgFUpdOSIElajcXnmCUnq65y0Mdh6cIPN_-Yk9O-ntvZExnKzmQYPHiBLX8CksJEEM6TW3dfaw=w1168-h876-no

The smaller ones are brass and have two crimps as normal.

https://lh3.googleusercontent.com/6rajAJX3qJmUCnAZvu8zdt4-7sSRsfXCKG4XotDNOkDoa7P-UvSB-n1AKwzMfdgIcfo3KVoxHVBBMjE0kdWBn_DaLgkmqd9GeyMeYoi5czW5XwA0VihNA0SJzDQPA5MnEQPBluG5cw=w1168-h876-no

reg/rec needs to be out in the breeze.

https://lh3.googleusercontent.com/GwcNrp-sLuEtBUDT09sFlS--kSk8iRr2EeMSoOJH11aiwMt2fnqApouPOllwLxgkAKg5p0XPu-JMyc1gx56IxmaGuWAZX8bQvxq1Wv2HiBx58GJ9t1aU1OJBHLGv1_-1VdEDLqyN5g=w1168-h876-no

I'm using multicore for the main loom. 8 core for the front loom, 5 core for the rear loom. As such, the wire colours are determined by what I get supplied. I did myself a list and have tried to carry the same colour through both looms (the white is unswitched live for the front one because it's the thickest wire and earth for the rear one for the same reason, they will carry most load).

https://lh3.googleusercontent.com/U1uBBhOmwQXwYTBwruE7Ihiv5Dnw1E-u5I2gTv09g7bvxwJymAixncJrq6jR-RJBUKgtp8kDJCwJrZwRnzVZwIhQO_u2o8uLQjClUz9j9xLTtCfyntFXqN4UZaws-Qge_WCvoiw5Hw=w1168-h876-no

https://lh3.googleusercontent.com/lv1HOfrA2pIDbHw-huhvRYwsid_AK2a7HqEEL7DSnTn57VU-E_3DsjJlpC1HGxYbmvDo-Wo_DNGEd4QwyMNifBPG2HoceFMhe9KXdiqS-9mKREha4cECqW-dPZ9l2daIMxrr3-j--w=w657-h876-no

Earths inside headlamp casquette, double bullet terminals connected to rings, the bottom ring loops back to the main frame earth effectively earthing the front end properly too.

https://lh3.googleusercontent.com/TLCFE3DE64984rXhSTaYUiZq5zQez0CK4Zwa7NpTIjPjDx59zad9leihJv2TiGM112vgewWOl1BUzetWJb4BSdaNWNaOzrTdoYs44CNT9_uT-B9iPMmoHDyzsZdcdNXyfxlilM9U-w=w1168-h876-no

Oh, another type of cable joint. A butt splice crimp. Crimp then shrinkwrap. Here it's bringing three earths together. You can also see the electronic flasher relay which will be hidden inside the tea-caddy. There is a bit of wire with PVC tape on there. It's just holding the two wires together, there is nothing under it, it's the wires that will connect to the battery.

https://lh3.googleusercontent.com/muhq7eWi8ek2iQoaoCSjgy5Q2tjhEyvxjCWgtUy7teiM4x4J5y9UUzf0GjWmbj309Q4Lpa7n-jdBycoONYO4GCnYAzvwA8MYAjTHJBwi_eNWg4TTm7cfTcifLR8wKe13z995cSLlzw=w1168-h876-no

https://lh3.googleusercontent.com/Kxf1TNFo7rJHZ6Uv99TX0M7gZdUuoropBl1EQcVQw2Digch1qOsXfqoQvZQBB1UkncZXOboI3qXesTJj-NqgVMr6ULFw0t-IXhX4YPAiLr5jqhaCZyZAt8-Zl6gUWoPiZQOl5TS7eQ=w1168-h876-no

This is the lot. All the wiring for the dash lights, headlights, ignition, flashers and indicators in place.

https://lh3.googleusercontent.com/dA5OtzVOtlKBFg0kiEhU3a2jDCFtN-VXQY7X6vZYGPH5F2IfldfTZ-SFEM_Wch6kMe670VVC3ZOHKdS2tIer3cSm-8jmPJ101MDglw7TfW6Iy1Kz8Gxv-Aeo-eXH3-NbNSl7wnng8Q=w1168-h876-no

The LED headlamp has a seperate electronics pack (to keep the bulb itself compact and cool).

https://lh3.googleusercontent.com/Z3iAHWKJwxJFwCmqWnI4-ryTVS8AVmbZqL4IWhJluURxdEAOgSL8pPPT19_xx3qijviVkExfJPZ6TApOdsutVEonAO6_49i0bSOJK_u0RY0GVTi3hVu5ZMoGB6P5VFW9j-iE0yDxeA=w1168-h876-no

Plug 'n play.

https://lh3.googleusercontent.com/SXPxYJEgHVuYfyg1uKubkHWNP9M9a31xVp-bkUv0VwlXeRGR8JUnwAYpMCvwjRr9opQK84sAn_iEZ9tXjIj2x6RgiRoavGxpVB4tu957d-DyV1SWp65eeV9g6Jq-8J9uGA7XMPwh1g=w1168-h876-no

Donk. headlight on.

https://lh3.googleusercontent.com/jUYaDrNQyETjDNlSolpqFpDiYwnJNLGI_XQYOE8p-CkNd1rMDv7EJ4WmgTbGq3PF7f8op24fnc-sLAKPn2zGyMxQzQIruiWKEnxpzMVoQVulSgvKvGb9S454LL2cV1tHjpzrtgnrQw=w1168-h876-no

Some details. I didn't have enough thickness of wire to be clamped by the stuffing gland so i wound some loom tape round it for now. There's the alternator cable coming in, main loom going out and the orange wire is the live supply to the ignition coil (keeps the ignition seperate from the lighting).

https://lh3.googleusercontent.com/dzjXt0rCDQ_EBvHA5sXUFO9W4ki20S2X9-b0zQWFUsA6com5Ga56C8x3XJi3-z_L24bXkKQdrSgj_gfrWHIAuDc2doM7oEA9zmJNQaersuUrNnDGaDEWP3prIAauYslI7eiTg2G-xQ=w1168-h876-no

Hydraulic brake light switch.

https://lh3.googleusercontent.com/W8wHZJkvxa0tHzlLMDJvxvM8lmCmjg_5zSn3D1p0RP-EcyrV74mXaBYXew3dXUxhpvllOVqUs8lQ11wLmGyVkEYb8If4NFsyoEfQkMqsHYewffiGUqdkcfDGqnjJC99yS8XPFX6Iwg=w1168-h876-no

This all worked first go with the exception of the position lamp which had unplugged itself.

A few cock-ups due to user error. I ordered blue sidelight bulbs by mistake (I read it a blue-white but they are blue), mis-ordered the speedo backlight size and the flashers turned out to be more oddball than I thought. As well as an offset bayonet, they also have a low profile globe so the LEDs I bought don't fit.

If anyone wants to buy 4, high-end BAU15S LED bulbs, let me know.

Still need to fit the rear sub-loom and lights but a quick measure shows the lighting drawing around 20W with the headlamp on full beam. Total output is 65W so I'm comfortably off for charging and my diddy battery should run the headlight for about 2 hours on a full charge anyway.

I'll save the "Blackpool Illuminations" pics for when I have the whole lot wired up.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 00:07 - 12 Aug 2018    Post subject: Reply with quote

I'm using a screw-together multi-pin connector and multicore cable to attach the rear sub-loom. It solders on. A bit of a fiddle using this size connector. SHould have gone for the next size up.

https://lh3.googleusercontent.com/7h3GHoe5O5RU6qW9ErWUlxmPCS9usE7lMfDGpmGZ7t5VVewBSfnj76XnCWLID3JqN7G0oCgUwXlEtbDhUm0b90Gp7QcSCKzg2NCjTMTAd4qdD243evvW3SSeuqOKG_ogOiLZJENRbA=w1168-h876-no

https://lh3.googleusercontent.com/j8f57-ia5ZqnGHsrtZtVqT847SSPSiv0lCxggB29qDwfQ0Y4TBJozojLM66GaQ1iWqH6VGMwBWmHSuywj0H-HUJVSG7FXqZ3eUTvwz75_7PzwaHnANuclNpIVcC5oboFR-6pLn2IXA=w1168-h876-no

With this, I'll be able to quickly remove the rear subframe by undoing this connector and loosening 4 nuts. At some point in the future I may want to be able to drop a different one on with a pillion seat or luggage racks.

https://lh3.googleusercontent.com/ifj7ZrRAluRhjPq0A6Pdd856qIsqf2EODsHI3zhQy4AvjQQQ11zVkg8s6vVitIqYi5O7ksZ2E9FnVVWirq0fV-5fdlQjybcjTEzCKTfaGJgvdmXNFEPXajRb1USEh2Ir2n--U6amAw=w1168-h876-no

All the wires and the battery in place in the tea caddy. The brown and black will be for the rear brake switch.

https://lh3.googleusercontent.com/9CO9cermtxXSjtbygWmfJnEh7SjckA5ARs0oE5sTqLXEKoQSlI-lW9vvhVy9vskctDREOeLi14u20mNtA4GiFFLNG4hn1KzyTpXQUlLZ_bjIHC2p0wChVtQOFVowQReRTYxHIScvHQ=w1168-h876-no

https://lh3.googleusercontent.com/FHjH62xwin8TX4FJHx-qWe9ymztbBGsLHj6ZClN8_ZolEvDPBqfBOe9TAE75tbPXNQIJgaBGugIN_MlMrDNCFKQq-TA-iJQK5IbPiVkK7n7ZoJe9zvvX3YGu2SvSZ5Pb4vgoRfsdng=w1168-h876-no

I wanted this style of lucas tail light. It's turned out to be more of a fiddle than I expected but I'm pleased with the result.

https://lh3.googleusercontent.com/hqPG5dSeviNqTzPPwm6ZxogZFlWl91ukujzecWbrUD5WDKmswd7K55S1dia3pFOlClA_jD5CCL9ziWc82TMKcmv33e5CCR39P77U-POV0rNmSuS0WZQKY_LHS5tPPh9DpClFgXguMw=w1168-h876-no

I had to order in 2BA threaded screws just for the tail light.

https://lh3.googleusercontent.com/FhzHT7r3GI6bdcdRj2DiQbClpfYrIymJ_a526mOCLulpT1Rb759YEPQ_nmZmplxTEBmw1VrATB5FllzfNiJqpeks3t3ajzqeOfG0P-iTscd0jLJW4r1iBi2l3kLGGZMvtovE0HxXNA=w1168-h876-no

Multicore cable should be very resistant to being damaged where it runs under the mudguard.

https://lh3.googleusercontent.com/u4WOX1ge4_SGmHSA4jRMc7GMKzl-fw3ZZea7qrT97I8-ZBdFDO36UctDUTXALye02I64C5qFb1QDzMcautnCYr34pcrtd2KHcCRmm7W3q66uNB3CACKKgtJoY5HASxO4e1niXswW5g=w1168-h876-no

As I said, purely aesthetic. Not really a proper enfield feature, you're more likely to find one of these on a BSA.

https://lh3.googleusercontent.com/gXBpjLm08FfhWVmFy27nPdumZmMdMSkDHxleAxpg-WdzyWo6QMPbdmejM3iJd6NTKO-S7_oP58umu8MzW8leQruILFJ066E73Aig6ZUI_81ahol88iM6y5q7zqQ7SyFs29MWHfZUyA=w1168-h876-no

Daylight running light (no, really, it appears you get what you pay for with LEDs). Doesn't even make the ammeter needle move when you turn this on.

https://lh3.googleusercontent.com/NkAjtQb5X0GnsO79kbJi-TbMYxrwUXq-cElgWaNqtKWD-dqcJX2yk7zkXIfsSrDCxtDYIz5T6gRcRBmFYn68ujhDRtAfA7szz6lASlFiTWbRdDvBOCAJzFnMyf3Nr9UT6ZlncJzR7g=w1168-h876-no

Sidelights.
https://lh3.googleusercontent.com/fs0MaIl3YH3F50ylYYjSFB7DoufRBXJEk9SE-iAnwgSusHCWjiacq_tNr4livGDMt0P7InZeX2DEKtj7hjq-ieEeu9WE54FTThKTEjsLa2McnJSp70iX-AFhaWEoOF2sbGxUB1pkDg=w1168-h876-no

Headlight.

https://lh3.googleusercontent.com/CyCeiYkJ7uX7GvKbA6_C8opbYiMEX_qEaoFA6yPbwENglcLJvmY7249mxapjkZvS6meM8B5HjeOG0kJdgERZqL8f-RIOwAnS69jW_-Kvkxi8U_ZmDc0W3INcKbuJinbtpwfCO2lM4g=w1168-h876-no

Turns out this speedo has a blue filter built into the light reflector ring. A little chavvy for my taste but ah well.

https://lh3.googleusercontent.com/UKmcIs0GWueWIoPhpJebDTyLoFeLmdh1eG65m3efbnwVyEnyPKP5IJnXBEEZE96j9qpD2gofcYaAP7bMZo6f_TtssLifebq34BeqRakL5kanezDpMtHBPol7lhA0JnGN1JVzHXoaDA=w1168-h876-no

The ammeter however,is supposed to be blue. This is my high-beam tell-tale (I may need to point this out the the MOT tester).

https://lh3.googleusercontent.com/wKgk9u0_7kqCh7kfy8mTDbb6s_STo1-uvIDzUJV30owDE4K0ZAtCQqG-mtvfp93NcLV39r7gYjEXEM3F-G2S21DRkKoMBxyzLfIg3jvsnXH21FO5Lp6G9gwlYZa6RyPsThMs8HbvmA=w1168-h876-no

I made a bent alloy bracket to take the flashers, it should double as a numberplate mount.

https://lh3.googleusercontent.com/IcH-2rrYlMLjFV1KlyDeH-gSyLUf9jUOUBCHg9ZhIutu46smWF0hRIauxs1oX1tcFCF9FG0pHApbb_EqA68VPC05gWxI2eeVV8AdttvcWYGOFJXSorjGS-YuFHkq5GvjP-O1ZUpuLQ=w1168-h876-no

Unlike many LED sytstems I've seen, this makes a good differentiation between the tail and the brake light.

https://lh3.googleusercontent.com/MekzQoDV1gehE4kCMyHpSqu47Cf2AdbJXjev_vYiX-mBEV3pEyUft2YAVx4oCSQbKH1T3GrIL-4YyeGlrRwC4KE0l8ro2w1Dvxt467LUg24adUrK0Eso2KZmPRmP9hwT7QXESu1gBw=w1168-h876-no

And that's it wired up with the exception of the rear brake switch. Still trying to find some low profile LEDs with offset pins for the flashers but it's not the end of the world if I use incandescents.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

sniff6
World Chat Champion



Joined: 23 Apr 2010
Karma :

PostPosted: 20:56 - 20 Aug 2018    Post subject: Reply with quote

Done a lovely job on the bike and it should give you miles of happy biking . Thumbs Up
____________________
'Great Britain' Love it https://img43.imageshack.us/img43/3967/67004290.gif or Leave it
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

BusterGonads
Trackday Trickster



Joined: 18 May 2018
Karma :

PostPosted: 09:12 - 23 Aug 2018    Post subject: Reply with quote

This has been a heroic effort Stinkwheel. I've just read the whole thread last night and this morning, and I tip my hat to you. There's not a bodge in the whole thing and I wonder how you managed to keep going in the face of some of the problems that came up. I'm looking forward to seeing how this engine goes when you finally get to run it and ride with it. Best thread on bike restoration I've seen anywhere.

Thanks for sharing the progress.
____________________
2016 Triumph Street Twin; 2000 Honda CG125; 1997 Honda Nighthawk CB250
 Back to top
View user's profile Send private message You must be logged in to rate posts

DJP
Crazy Courier



Joined: 11 Dec 2011
Karma :

PostPosted: 11:08 - 31 Aug 2018    Post subject: Reply with quote

I admire your skills if not your subject matter.

This thread reminds me of the 750 Bonneville that I rebuilt a decade ago. It was all done properly with all of the sensible mods included. But the sheer horribleness of the basic engineering put me off of riding it and it was sold soon after completion.

The guts of your Enfield remind me of that bike, sadly not a pleasant recollection.

Well done, but rather you than me Sir!
____________________
Suzuki Bandit 1250
https://deejayp999.atwebpages.com/index.html
That's http not https
 Back to top
View user's profile Send private message You must be logged in to rate posts

.Chris.
World Chat Champion



Joined: 09 Jun 2007
Karma :

PostPosted: 14:19 - 31 Aug 2018    Post subject: Reply with quote

Quote:
I admire your skills if not your subject matter, etc, etc.


Agreed. This is a fascinating thread, and thanks to Stinkwheel for keeping it updated. However... seeing the crudity of the design and manufacturing has extinguished any desire I had to own an Enfield!
____________________
Chris
1985 Kawasaki Z550F
 Back to top
View user's profile Send private message You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 17:00 - 31 Aug 2018    Post subject: Reply with quote

Cheers for the comments guys. I don't have much to update for now. I'm currently working on the front wheel and making a new calliper mount.

It's got a saddle on now. Springs on powdercoated frame.

https://lh3.googleusercontent.com/8QMjWYinForf6OHvKVRCS8sOP5-v4nMHVVkGQznOJeTQ4hnTbfu-wMMYZCmlNoOE5gxyJ4yax7OAnwASirHi1utRH2T0UZVrPVKBa_kaJuVenfv6AtZbppBpFYJt1mQYYGuw9tnDaw=w616-h462-no

Old leather jacket.
https://lh3.googleusercontent.com/J0R1ZjTcSu06duXMyPl04LYBMHQEiFEc0Az_DFzrIbczrVnE4KJQJgBNBbZTGDov-htX27Y7MBnZ3Svka_Oypk3Ed45rQRHj9KzInX0hJQanloxnNZLQNyKg0KxZbnxAwPzDNSMJbA=w616-h462-no

Gel pad for my poor bottom.
https://lh3.googleusercontent.com/rXuX5G4uyMPF0CotM2mdSI1NVIcgaNng8V7UeWOBIF7NrUv8MkSL4M9rRYlWrmFXYNEaTjT3s7C4SskNryAwsrYGDxOhUOIjtR7uhp_sC-hJlXKka8P2Fw-z2IA48JaMYxLiseT11w=w616-h462-no

Cover on and nobody would know.
https://lh3.googleusercontent.com/xpFrnM1YRAwfjfM3k4BtEGQjtgmahVjO9bDkIhjY8ORjCs8_33PcyHt_tkp-SYnhqWqJZchUufnNhPKTDR-NI04xFRUpLlnqnelWtI8qHTN3JBU0jkQNgyJlMfK6e8mXl3W4qIoTng=w616-h462-no

Sticky out thread crying out for a pike nut.
https://lh3.googleusercontent.com/y7XcqiqjNdCk_e2gMLuFXY-kWT60O6XD5ln0TJuMgS7-KqWifer4n1OiUpDRWqMru4ya__oGHANxUI9FU-kvXXZ0k6sXGGqjNrNUkd8owOHvI6KEhoXOSHuitIKMLMDXIf89PHP8IQ=w616-h462-no

However, they make a BULLET nut!
https://lh3.googleusercontent.com/AN14h1ni5CAO8cP9A-mAQG0bzs6ZY_fKqcMxXyH3GKVMdiOpHnaKhStkj2UbCtifVzwW2gm55_nCbPRBofKTM9whaO_gFIa685AxAzfIvvDBekgluk002fp6aip3zlZf9rX4KVmyIg=w616-h462-no
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

P.
Red Rocket



Joined: 14 Feb 2008
Karma :

PostPosted: 17:45 - 31 Aug 2018    Post subject: Reply with quote

Seems I didn't post my other reply.

With the mix of wires, you've done + white on one set and - white on the other. Assuming its because you and only you will ever ride this, just wondered why, not a great colour option on the low amount of cores?
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

virus
World Chat Champion



Joined: 17 Aug 2006
Karma :

PostPosted: 19:35 - 31 Aug 2018    Post subject: Reply with quote

Have you not managed to take it for a spin on some private land yet?

Id have thought that would have been about 15 mins after the engine first started Laughing
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 14:55 - 03 Sep 2018    Post subject: Reply with quote

Paddy. wrote:
Seems I didn't post my other reply.

With the mix of wires, you've done + white on one set and - white on the other. Assuming its because you and only you will ever ride this, just wondered why, not a great colour option on the low amount of cores?


You don't get to choose the colours in the multicore, you get what you're given. Also, the multicore to the rear of the bike is pretty much fixed into place. It's not like you could pull two terminals apart then put them back together wrong. I've used black again at the other end so it's only really the one white wire that's oddball.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

struan80
World Chat Champion



Joined: 04 Nov 2014
Karma :

PostPosted: 02:57 - 08 Sep 2018    Post subject: Reply with quote

You could use cable idents.
 Back to top
View user's profile Send private message You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 23:37 - 14 Oct 2018    Post subject: Reply with quote

Been ages since I managed to find time to work on the bike some more.

In fairness, it's nearly finished, a couple of jobs still to do though.

Blanked off the spare mirror stubs with dome head bolts.

https://lh3.googleusercontent.com/sRcqZ0dBihewzTkKJx0eSyChjco5-Pf6Fay-6NguMg03Qw4vI0ky0CM42u6DT5ZPPXlGJtdQZ3iptaaJFmbBu-ZehdOFvw0q4L35KI6d5KA5T8KbNLSwoYGevlitqkCJKP6G5aK4Og=w1164-h873-no

Fitted the worlds longest brake lever. There's a finny little metal thingy that attaches this to the brake switch but it goes inside the toolbox. I'm leaving the fitting of painted parts until the end so I don't scratch them.

https://lh3.googleusercontent.com/EcmISOIMvgUBvzNbQWVEOBBAEXT5a_4lssyTJtBnqBZ6vqOMZgwvoLcZiaE_8y3SGQ_vgS71fWROZopapkczwW3wcTuewpjpzBViB3l8Y8TNbfD855JSMs0y8rlvaFulKnEarXWX_A=w1164-h873-no

https://lh3.googleusercontent.com/NvG8hk2Ym_nIXvoyAGLD2DleUWskuQJ3C2iIDgkgVHn3OAkZFIohjxBcskKaQu-VCYyduhsiJPi0k9WbPeQoZo0H6n7_ijHi4hxCLZ94MoiKSEnfUsV3f6kHA7ovaz-DI82L2l9Jeg=w1164-h873-no

https://lh3.googleusercontent.com/-F0QXME72_4va5R8N7Tb17SedZXyzEtPlkfbsJ_64E8dMPrnXcOrrQgafjL02nqNyqpA26Hx8iM_Ha8RHrqMO-fbI_1XeZ1LYg43Mb3wYCfMiPr2Wx6XY5igfhJwxItaU3PZ8mMgaQ=w1164-h873-no

Clutch pushrod. It fits right through the centre of the gearbox mainshaft. As standard, it is one long rod.

https://lh3.googleusercontent.com/wrn2JqDBBFfyiNCDMUYkWTU1YRdQXXxzVavngvThNtf9013e8teWJuKPYe9bDAhZJY32nIE3dNkQutM2oPNmwzFOqPlkzUWkZ0p1cYtuqMV9TEtcZKSMLsXY__muOCDOIrHkBIuhpA=w1164-h873-no

They have a tendancy to buckle slightly in use, they also heat up and start binding on the inside of the shaft if you do a lot of stop-start riding. Part of the solution was to fit a ball bearing between the push rod and the "top hat" that disengages the clutch. This reduces metal-to-metal friction and lowers the surface area for heat transmission along the shaft. However, ceramic ball bearings are even less efficient at conducting heat.

https://lh3.googleusercontent.com/4tDdiweeJzuraNNJCwnhy1yhGXwK0t_yK618hrLSQ2eCF-sUEhOk8W3P1YdyYA6kKipvy2yYhwvEjgnH6ZERlSgMOJYVLACzHUGHJFHD63qrreP4rlMYbE41MASl2ClpcDEXSS1jJg=w1164-h873-no

Fabricating a new clutch rod out of marginally thicker and higher grade steel also helps reduce both the buckling and the friction aspects. Piece of 1/4" EN8. Length is critically important here. If it's even a couple of mm out, the clutch will be impossible to adjust.

https://lh3.googleusercontent.com/jn8OLpS7Ht0PEy04639m_kcmcZgmsoksGJEQ0CS5AZlp2hJ_D7OMgelEHQMvpDQFlqbYDi7VIJ4eJnwMjJ3pZL5tVN5rPzU0e4EttwJsKgjswOjGRY1ip2bzXPuzatJ004dy28k0Uw=w1164-h873-no

The ends of the rods bear either against one another or against a ball bearing. So the ends need hardening. EN8 is easy to harden. Heat, oil quench, temper then soak.

https://lh3.googleusercontent.com/DOyCV1ooyjcmfR0kqDmqFyZlq2W4FbiXrFcUpeS4OOX14tDMP8uoKu5AyzAcPFqShjDq0k8AhbaiQLJSRHGmfkR7WevjL95MfwfiCM_3hCowxiwLyFw9wwR0TiqhQkvFMoaonYBxcQ=w1164-h873-no

https://lh3.googleusercontent.com/YhtcVEskJBBbiDNx8c-vYWD40pKlKdf03P842dblLPQcVDZCec6QEDZDUgjvZNWdRir8bGv9gJqnfLtsO8up29M67HSfPFGm6Xd9lgQNkxNpBEH6K9oOYPz04venOUP0_KMIXXIeEw=w655-h873-no

I also replaced the white plactic mudgard section with an original metal one.

https://lh3.googleusercontent.com/e1d0zxQJw2uFqqCINCndLCY6fwrhMjVXrALCJGK_bEZ07yXwXopV342J5yStV4ZFP9a2VJ-wedT6VjrmiL4PHHVuAQEZiBW_gjp9LrajPREyjqru_1oO_Pwce8bT86Cu7FSvI96PaQ=w1164-h873-no

Next job, front brake. I've decided to just bite the bullet and fit fork lowers off a later model with purpose built calliper mounting lugs. Unfortunately, the mudguard mounts are different meaning I'll not be able to use the fork shrouds. A shame because I like them. There are however other practical over aesthetic benefits to this as you'll see soon.

https://lh3.googleusercontent.com/skqXXg61n_BuYzceXhzmv6dUxguQKw9q-Gi4qS9wuCVokxCI4wkinBb0aT2leWgMK8xU_iahtxeetPCIJ12yyKWuRz4zYOx_5Rqr8vnl6QLM0Wb2_4x_J1pBXPe0zgaMpDK27VnQwA=w655-h873-no

The shrouds are still required because they hold a piece of trim under the casquette. The later models had a "shorty" shroud. I just cut mine down. They are only a tenner anyway.

https://lh3.googleusercontent.com/iw6OQb0TjhMwBEHV3XLyadehHNAyNJaNFb-A9hil8C-k0FP6qV8EUQU2MtBB_uadczWlajYXAIGmVTgu-3d0EqKmlpfjczCz-Gy7NgTxklXMrSq2oNEhlGxeg-BAZOfVT1KbqFFgtQ=w1164-h873-no

New fork leg showing beefed-up calliper brackets (the brackets on the other one are for holding the mudguard on)

https://lh3.googleusercontent.com/XCZkIaRobS5vB_gaamYaMb0lLljzzTjzDbILKxrN-DGFcGgDypTaSSBYDovdD4hvTvaeQ4YcdF52g8wf3Vg8v8JrZZFHquYWPQ_EVkzDY1H270Ic0DNP7p-ycMJn4uNdPwfxeLFoVQ=w1164-h873-no

I helicoiled these holes from the get-go. Saves time later and they are easy to get at here.

https://lh3.googleusercontent.com/zMyXvhvYpBUZkIuWTBVHMF0MLirbHXf9fkCaDZITnPqN5GCuRMqHHS2YRQT8HtUIomXYWUHUADEgHoMOaGlJ1DinyvZTMBWzxmNq1yOBc73qraR0uW_DbW8hRUfD2F8Lbw4w4AwzaA=w1164-h873-no

So gaiters instead of shrouds now.

https://lh3.googleusercontent.com/LWbiu4eHE4RxEGDGtv3f5OrtpcO16QDx1K8oUexp37VCCbJnGQJHVnN1HUST3RiVXwHYQvLd5Pm3FyouwVFYC_JhQSp_qrH2X_GbCzuBubxfW5-NXmUF1-euvzfopO20aO8rXKi8CQ=w1164-h873-no

Disc brake fitted and system bled. The Brembo radial master cyclinder works well and was a piece of piss to bleed thanks to a top nipple on the cylinder. I'm going to rebuild the calliper with new seals but it's easier to get the old ones out with it pressurised. I've also cross-referenced some pad part numbers and I'll be able to get brembo pads to fit (same pads as a 2013 KLR650 of all things).

https://lh3.googleusercontent.com/tCDA_OBYy62BouO1_MBOVOejIzn5EJtLueskdBoCW48225L7bWKXv3QuAixdCOMkpP9U-KmpAsGKEUO95Ug3PmyXRT3FSiIe5xqhHt7EGERKKvjx1pBAEQhdBJ0LyTmsCnM3Vih-mA=w655-h873-no

https://lh3.googleusercontent.com/89GCvdmL6pTyOMvLvtojI_Jf5uf0ShFoykAKqL6_RtCNTjNuWzwJS21pd3P2wLsKXU76iwfKHL5B9SwJX__84ODnTF6V5VvT8XqsoCPKCzAiZ0ADsPRPA1XTNfNTIctAdxDY2HB_UA=w1164-h873-no

I ordered the wrong wheel spindle though. It was from India and the advert was a tad vague. This is off a later model and is about 1/2" too long. Again, not the end of the world. It was also only a tenner and I can use the spacers and nut with a UK supplied spindle.

https://lh3.googleusercontent.com/xQwHg4kwC-AyTSm2BgP5FN5u-XwejsVxbM6rAqwz4LX27dmKBDK50zISxFoVS-LN3PsNvnYIjQPfaC03uIcFrpsvMSbL-cCPfJTfzetQ1SxuReMsN9lba7ttwE_wXPPKiV2WzXPnrw=w1164-h873-no

So. I need a way to attach the mudguard. The more conventianally located lugs mean I can fit an arched steel fork brace, like you find under the mudguard of most Japanese bikes. I spent a lot of time thinking about how to do this. So. Bending the steel to match a curve I made with a bit of wire.

https://lh3.googleusercontent.com/CaQozeTptZhPzc2TvUcdwOCXe5vF1Cqn2dEI8yVAYlbBpT7cbtbz-p7RxxzNoBko0XovLHXxE_zLQexltJh5Okz4RsuvP3Um4Rume6LKpNLNOrcKycBCVoCpubJ20MHT7VaUhiNgBg=w1164-h873-no

This turned out to be damned near impossible to get right. Especially without an anvil. 3 feet of scrapped steel, a sit down and a cup of tea later and I realised it doesn't need to be a curve.

https://lh3.googleusercontent.com/-aRMPJivCeNYS0qbELNsN3fQ9MuNmF17O3Tz8GxdhW84JSqlncSoqitGUZJuwvH9VH5-YWpSZEmJfAmsz3X48kZiR3WbB5Tlyo9sXuXzdZ8Tst419Jj7fMmNHo9iFD2FBtbqo_Zf3Q=w1164-h873-no

Two of those and weld in a bit linking them and I have a fork brace.

https://lh3.googleusercontent.com/vXe6gMD0IUmFhBFlCKTF2ilKL0s-7GOZ9btOVWb_4WQRg02gnU2tuCMoDPjajBetm-yKm9J5ffpDMRksi1GyvTIVnwqvzSgYGNXX9Wp4lT9VOGqBsePwWbA7VqptAwVRYbvMWDAX_A=w1164-h873-no

Perfect as a mudguard bracket too.

https://lh3.googleusercontent.com/DctIk2mKkZOL6eihBAW0wdgoGGkgIWQtcVyvJCwxpX-wOomG7uEMWzrJvTWwSv6q-LICmuGOSFxGct3giWL4GxxmVuQSjzcB4CoZrporjHxGUoFNBlyPPmiF26psVUi0xDJz3x9ttA=w655-h873-no

https://lh3.googleusercontent.com/IwFCeP_Qc8Ve3Exuy3EkvnxrDmLqYQLHJ7RD1LMUai681qDkG-V2Baand5HCwwQ-OgAX5QUqTOQR6KPloLVoWybHjyjgSGW1pFARENQ2mLTtJG_b6--A9nbzuJWDuXLnJ2z_btYc_Q=w1164-h873-no

https://lh3.googleusercontent.com/DqPkEjHc4zNEZygww7tThn6wPsXbSUymBCXXLRFKwbVznOOCv-z5yVK4N4xT2i01wROoSwCEd9Nbx6VD0xs8Z1jWxb6MAOeKXd6KJeLsleDUPqmGd27DR0R_sbwMC2TNi-tEczWQAA=w1164-h873-no

I've ordered some zinc-plated button-head fasteners to attach this with properly.

There is (apparently) very little left to do before it's ready for the MOT. It wil be getting an new rear wheel. I have it but there's no tyre on it yet. The one that's on will do for the MOT.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 22:28 - 20 Oct 2018    Post subject: Reply with quote

FFS!
https://lh3.googleusercontent.com/ZCtPMT57EfJiLhFyNVhkrgTMh8Bvifa4dUsOQI6ze_gTOZcfBru17mMCGcc9W4NYc2FJapOs173UxxUzeb4jkxsCQvXOS-0nTWfJxyij55AAdGzTNIijI-oNZkwPT4_jGRmOzgR9Hw=w1164-h873-no
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

Stalk
Brolly Dolly



Joined: 26 Dec 2005
Karma :

PostPosted: 22:29 - 22 Oct 2018    Post subject: Reply with quote

Sorry to see that. I have been watching and admiring your work and can only imagine how frustrating that is.
Weld or new leg?
 Back to top
View user's profile Send private message You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 22:51 - 22 Oct 2018    Post subject: Reply with quote

Aye, frustrasting but not the absolute end of the world. They were a set of Indian fork legs so not a huge amount of money. With India, some you win, some you lose. I took a gamble paying £35 for a £100 componant, this time I lost. I also have a set of backwards toobox locks (the key only comes out in the unlocked position) to go with them.

A new set of ends en-route from a UK supplier as I type.

So weekend, got the fork brace painted and fitted. Now needs to be removed, I hope to hell the holes line up with the new forks!

https://lh3.googleusercontent.com/lk2nhhMsAnVbT1yAl6Kfc4luYeOLcDBOpibxWL-aHcjYaMW77jFS_DNBRzWzdaecyEF2I5k85e-n5DR5l5W2eGStwGgpFi6nXFCGZQMuLHzW4ihTUhG0Jyfi6djBfYHpt--zni_Igg=w1164-h873-no

https://lh3.googleusercontent.com/9V-1Bl7IhRnwPFIs4RF0HqGOFQGZU9g2BsYzJdoqhEG-iT-lKXdYYblYTwcJh2Dj0hlW3Z-seEJXxNN3WYRu4pdQzeXiZeC4h2-SmRxRF03mRhE_OJMydHBGEFTmOXrWxBpLIQKHJg=w1164-h873-no

https://lh3.googleusercontent.com/Iy_O47ad89o3kGXaM_7STRPOIm3sdJ00QqY2b_eACU2UQWZqTCQsPT4tUgsIgIJqiwqxWsW3kRg0HYYAS3QEEqBMLy5V3gjF_7LZNpsfrIsxFBTCeImqIHqn6cyENgB7-QK4hZHbyw=w655-h873-no

New, correct length wheel spindle arrived.

https://lh3.googleusercontent.com/F4JSkscS7Amrt-3SdANC74CZB6EuEsr2Q3ESjRTyobCaeOt18jX5Kdo4mvbrpNUUMrGWkberKiEwuugIvVsWkf0lu-7cWUQd8lr2Y0-R46BSU0dbxog7yNoQ7oApO-lbB235iUjlWA=w1164-h873-no

But yeah, mini disaster with the clamp but I suppose it's as well it happened here than on the road!

https://lh3.googleusercontent.com/y2qkw2PBV7yxM7gIoNLS99LJGFB_gYM5a_YMR_R0DFEuwYKCYeM5DQMrVdgOR4mZOkJ9ZMDHXlEdCW7BDRUxX0nDr14ItNjbXhkRhnc9qILrTAa2gBTZfU66v_QC70vTlqJL1mjzMQ=w1164-h873-no

I also stripped, cleaned and re-built the brake calliper with new seals. It is in very good nick. No corrosion at all on the pistons. I'll touch in the paint with some heat resistant enamel and a small brush. Took about 20 seconds to bleed!

https://lh3.googleusercontent.com/CgFWi6jB0wLLsMuDHS_Ii_xxdcV-J-RWiTCCMFEk_1303MO6zIwexoYhpOBoVKag5uhUWQmmnxpyQAnKJ96c8vnNqct3N3ogIJJZanIj8GRZEyYXKMIeQX9Hg3Lnh4K9XORW9QaJaA=w1164-h873-no

https://lh3.googleusercontent.com/pr4mdHI9nugVUxtfScdzyxJDeiyBsgjJWPi4cMNB4zo9b9wG2V1_dYeeYnuyLyRrfztNyMb4GMYP44gEEaIMMmeheINVaBz34uuAHPRYgNGiPMwBoUBWf1zLWy5fPZp5_3aEsFe4Vg=w1164-h873-no

Primary drive has a huge rubber o-ring that goes round it.

https://lh3.googleusercontent.com/pFakLxthe0oi2w5k13C1eFORCuesMcBdHY24U2ViP4QnJcP4nJ45TbYKkKYM6FfqpWMsBe_S85gQWQTUZXVj2s0g-4t8OetnEp9IsBVzSx7wnqJ9pp_qI3L12WjpgAPRMyzj8pJZ0Q=w1164-h873-no

https://lh3.googleusercontent.com/VxU053G10Q7Gcbw8PKOyQtO6NHSRgfkxxzWrJrddxd_xpJ1ccqGUFWbsGeH82WiUnUQaWe8ITBuwvck-PrJtHHDRkZrAMRWuKJsFWYC87XshfaNLckj0HPXrM4lBQ7y_X_gTG1locA=w1164-h873-no

Cover on and filled with ATF (manufacturer stipulates engine oil but ATF takes more of a beating without frothing).

https://lh3.googleusercontent.com/2vKRrjW22UOLs90q2MRRgPGftDa1Z8Hcl3jBWkeTcTbS_RH8c-0Eiy0lslANzWqBu1AjCQZ_43crxt-yg1rX1iZbBokxnDL2uqg6sD4ewVcC_mMHvRzutMGmgeqmAosyQq96HbUZKw=w1164-h873-no

Also fitted the LHS toolbox so I can do the brake light switch which is the last of the wiring.

https://lh3.googleusercontent.com/CXldfGh27Qz6JZ8EON2dkPIl_jLwD14DuOd_I0MbYznSFPhfm9MQlIaglYZ4-GKt4Rf-SqIrkkT6qr_k2nG12AXpZ6nPCBaB4an7-nbop1HnAAJuF8s4hNHHzhCsLh33iLjxS55U4w=w1164-h873-no

https://lh3.googleusercontent.com/h_TBRlDbaQb5B6AfJBvHlb5MP0WebiDMEp4RElJHYKYbwVvw7Oq9DzG1y6J_-K08TfnUoi0_KuMYe_0nOEJMRvPEo1OLnkixH7PNGOeo2XBlw7IetUpP8mLgJu6muUokw1V25-Wf4w=w1164-h873-no

Funny brake switch widget.

https://lh3.googleusercontent.com/Z4QHH06wtM_ZlCyeX6Qj3WYoRMhXRhJTDDxDRlLEXcohhwnaApF3b1B25X3fLdru76ueBuTh6VfGCMznTe6nU1xVGZl7DQCCuc2X8Z3oqU3jHk9d8CaRUxc2yPwaOSvrNMnSq9Glug=w1164-h873-no

Running out of stuff to do now.

Grips. I have big hands so while I generally dislike oxford products, they do sell extra-wide handgrips.

https://lh3.googleusercontent.com/WmeByqwP3xskB6CoVwTLQ4mXhHwsuvJQz_NcHS8uKvo8GJFuboyQlulODqukvVGbehE5Z8LEhSWsLrhL_cdXi99ZGjPOLZ4aeFslX8bF9dJKtAyHRj_fibLm1J5ENSjfdUlqeM99hQ=w1164-h873-no

https://lh3.googleusercontent.com/iDKGBB_ctoh5HO2eQMn-D8jrZ0HDPtWRuKqG92XTngeIg8mifnEf1vAw1DuGQFG5dwEcSTB-wa2f0ug4q4AucTD0gyp7yCiB0fgUqxq1pJzIWSgoU6LU7guziF2UEqbn27w7QQA-PA=w1164-h873-no

https://lh3.googleusercontent.com/1X3NMuBSj-rdNWYD4LL1-eK6HHzNcf8DMuwI_72_hjr9z6HBkEHvq0LrFDQAl3qqvpuaM1HpuIy7FknI_B8NLZaY8DtS6adIUBIaYJFJySpKv8GmMapfCdsvsnKWo9_yh972LbrT8A=w1164-h873-no

There REALLY isn't much to do for the MOT now other than fix those forks. Tank on, RHS toolbox on and some way of hlding said boxes closed.

There's a lot of detail that needs taking care of. Rear wheel needs changing out for a brand new one I got on ebay and it needs two new tyres, maybe a little mudflap on the back edge of the front mudguard. Decent brake pads. Be nice to have a diddy parcel rack on the back mudguard.

Also needs insuring (lube up!). Plan is MOT, swap engine number. Run it up to temperature once, change the oil, re-torque the head and check the tappets. Then up to temperature again and, providing it's not running outrageously poorly, go spank its arse up and down some hilly local back roads for a couple of hours. Another oil and filter change, re-torque and start tweaking the jetting/timing.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

pepperami
Super Spammer



Joined: 17 Jan 2010
Karma :

PostPosted: 01:41 - 23 Oct 2018    Post subject: Reply with quote

A good job well done Thumbs Up .
So many people put an engine/bike together and then think it’s all done.
Shake downs, fresh oil, and re-tightening are so important.
____________________
I am the sum total of my own existence, what went before makes me who I am now!
 Back to top
View user's profile Send private message You must be logged in to rate posts

BusterGonads
Trackday Trickster



Joined: 18 May 2018
Karma :

PostPosted: 18:38 - 31 Oct 2018    Post subject: Reply with quote

Very interesting tread this. Thanks for keeping it up in such detail.
 Back to top
View user's profile Send private message You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 21:27 - 03 Nov 2018    Post subject: Reply with quote

https://youtu.be/Gh7xCtV5TNQ
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

MarJay
But it's British!



Joined: 15 Sep 2003
Karma :

PostPosted: 11:56 - 04 Nov 2018    Post subject: Reply with quote

stinkwheel wrote:
https://youtu.be/Gh7xCtV5TNQ


Nice work sir!!
____________________
British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 15:25 - 04 Nov 2018    Post subject: Reply with quote

It took a lot of kicking. On my first attempt, it turned out there was no spark. A connector had come apart inside the electrics box. As it happens, it was the one bullet connector I didn't fit, it was already on the end of the CDI output wire when it was delivered.

My intention for this weekend had been to fit the new fork legs but I got them out of the box and they were the wrong ones. Rolling Eyes so back to the shop with those.

Mounting the tank proved to be more fiddly than I had expected. The engine is at least 7.5mm taller than standard and I knew there would be issues getting the rocker covers on and off with the frame clearance. I hadn't expected tank problems.

One of the seams on the tank was fouling the top of a rocker cover nut. The following picture is after I ground 3mm off that front nut.

https://lh3.googleusercontent.com/Fscsg07OFZ1SHH8cOQTdD4PBAB7Rj8IXgY0XRFw8cO66oNoszUDqpWtbF_zQZkUa-i5aMVXym0K8mBo19nc3rQWa9BYrzcP0UCx4Bx_K4xQ-67QsqLslpQwvn8SPm8AxbTtEj5RctA=w1160-h870-no

Despite them supposedly being standard fitment, I also had to lengthen the oval holes in the rear tank mount.

https://lh3.googleusercontent.com/-kRIJ-3ory2bMsN88e_PQy4VOMfZZ-_9gLESJL9XYsualZpjOCsT4j2cc3tlgT_zU_TeHVg61Sa-GF0xxbOXX4zAdqWyotgicf2a-8ZVwWO-Idr4tY4lZzMSqUeKs1X5lsooj-4Czg=w1160-h870-no

The other issue I ran into is the fuel tap. It's a standard one I fitted but the rubber washer in it is really shonky. The fuel flow is way too low, barely a dribble. You can see me on the video fiddling with the carb a lot, that's because it wouldn't tickle properly. I think it would have started much sooner if I could have given it a decent flood of fuel. Got that swapped out for a different one now.

I fitted the other toolbox too. The locks I got worked backwards and I'm not a huge fan of them anyway, they always seem a tad flimsy. So I applied a little lateral thinking. A long extension nut attached to the inside of the box with a strategically angled alloy plate.

https://lh3.googleusercontent.com/yuNBU2Cpkx1wiqqpQA1AFwlAnbZajbUzIJgcAsVQt_9jYxuAvmn4YudzFOgYQCTw1CLHTLB6SO3Prr_BWzm5Bjv8QaYmBT_CNjUDi3hDRE_93AAXmX9tL_TaDUi50tXcM-rE4ksBEQ=w1160-h870-no

https://lh3.googleusercontent.com/9kn7LKbOFfMS3HKGE9dLXFp7zZrb2VNY-bHL40uFPUTl-EQDnyItchRHfy4pXULf1Bw_VYK-e4QUDVyVUJ5XVBeHxm7YoB31wgqSu5aEHa30za2nPdxzQ5VWQFZUafcwQxVdCITg4g=w1160-h870-no

Then a couple of stainless thumb screws with plastic washers under them.

https://lh3.googleusercontent.com/PG6X2R_z9q9sST-eUqnbGZ9G_MFydAYGx05-2IQow7nuqkuEe9BeXnUznsWsmMjjSb-ZqIYaVrw_1n6OZGZF-1MrKLw5OaZevfMkLg7F-8TPyy5DIwGmjZ-I7Q768sQFfu_O-SOw4g=w1160-h870-no

https://lh3.googleusercontent.com/nClkd8ALsbkh5gV6MorpzBVHcaCCYiCBiy8luRbDk2vGa6cjj5ZGxUM7PBh1u2T-O2cLInOAZ9xU_FM-ItIODXTBTop9LVRLK0ku91yn1z0i2EBOUcViWSzZ9JSzJ8iwQpBZu1Rd3Q=w1160-h870-no

After the run up to temperature, I re-torqued the head nuts. They all took at least another half turn.

https://lh3.googleusercontent.com/FqxOPFxIam6x14jgeTEJqaJ6Q0437IzkN6NfuN8oCgQdyN5b5Lmnb5aibHKm0TWmzB5vrvw2fwgWJOGCgh4DdrhPPK5fBS_meZYF4gRVYwVTJvrJdzXx26S_aKorYxHzbAI7XUXtFA=w1160-h870-no

Also checked the tappets which, despite having tightened the head further, were a little on the loose side.

https://lh3.googleusercontent.com/4iwAu5OsgBv7zF70hEBE25uvUfJ9_NLDE3LOklW5Kf_zslb2Mmmq_L-q2BKxFIYVAP0_ORpkz7WRwlenzDK8vip8278_A82cJzfbCuSEuKJlGTA1kXXWUjU2JFr67tpqbSDnTiJFyQ=w1160-h870-no

I don't think I'll change the oil until after the run-in. It's pristine and all the oilways are well primed now.

Oh, I threw a little filter on the oil tank breather stub to stop small animals cralwing into the oil tank.

https://lh3.googleusercontent.com/TQWhsD2_fxzuMWbozlPId-OaCqoXWEheS6TrlqO_OeT1WoQkG89cCf6oqPd6zOdX_PYf_2-8VmEU0vkk_fynoghhFouKk6wmjz-QSu-fk_HA7fhSNbRLymfZ_KXQm55vXyw_eeCk9A=w1160-h870-no

Law of unintended consequences in action too. I noticed a rythmic clunking as I was pushing it round the workshop. It's the heads of the chain rivetts hitting the slightly protruding end of the rear brake lever pivot bolt. Ordinarily it would be well clear of this but my huge front sprocket has moved the bottom run of the chain down a few mm. The old one was a bit worn as it was and it's damaged the threads removing it so I'll need to fit a new one. All it needs is an extra washer behind the pivot.

No pictures of the complete bike yet. You'll have to wait. Tank is back off and in another room for when I do the fork legs so I don't drop the bike on it.

SO nearly finished!
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

P.
Red Rocket



Joined: 14 Feb 2008
Karma :

PostPosted: 10:43 - 14 Dec 2018    Post subject: Reply with quote

stinkwheel wrote:
SO nearly finished!


How finished is it now Mr. Green
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
Karma :

PostPosted: 19:08 - 14 Dec 2018    Post subject: Reply with quote

No further on. I broke my shoulder (well, technically arm, greater tuberosity avulsion fracture) falling off a ladder about 4 weeks ago and can't really do anything much with my right arm. That includes lifting a motorcycle onto a stand to fit fork lowers or loading it into a van to take it for an MOT. Only just got the go-ahead to drive the van, been on the bus for the first three weeks.

Parts are sat there looking at me accusingly.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
 Back to top
View user's profile Send private message You must be logged in to rate posts

pepperami
Super Spammer



Joined: 17 Jan 2010
Karma :

PostPosted: 20:05 - 14 Dec 2018    Post subject: Reply with quote

stinkwheel wrote:
No further on. I broke my shoulder (well, technically arm, greater tuberosity avulsion fracture) falling off a ladder about 4 weeks ago and can't really do anything much with my right arm. That includes lifting a motorcycle onto a stand to fit fork lowers or loading it into a van to take it for an MOT. Only just got the go-ahead to drive the van, been on the bus for the first three weeks.

Parts are sat there looking at me accusingly.


Ha! Just a broken arm Folded arms you could have used your other arm Rolling Eyes .
Still watching Thumbs Up GWS.
____________________
I am the sum total of my own existence, what went before makes me who I am now!
 Back to top
View user's profile Send private message You must be logged in to rate posts

P.
Red Rocket



Joined: 14 Feb 2008
Karma :

PostPosted: 09:49 - 15 Dec 2018    Post subject: Reply with quote

Ah man, that sucks Thumbs Down
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts
Old Thread Alert!

The last post was made 5 years, 105 days ago. Instead of replying here, would creating a new thread be more useful?
  Display posts from previous:   
This page may contain affiliate links, which means we may earn a small commission if a visitor clicks through and makes a purchase. By clicking on an affiliate link, you accept that third-party cookies will be set.

Post new topic   Reply to topic    Bike Chat Forums Index -> Show & Tell All times are GMT + 1 Hour
Goto page Previous  1, 2, 3, 4, 5, 6, 7, 8  Next
Page 5 of 8

 
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot attach files in this forum
You cannot download files in this forum

Read the Terms of Use! - Powered by phpBB © phpBB Group
 

Debug Mode: ON - Server: birks (www) - Page Generation Time: 0.15 Sec - Server Load: 0.32 - MySQL Queries: 17 - Page Size: 191.51 Kb