Project: Garage Find

[andrewsmith]

Cool
Don't nip it!!

[Mauler]

Impressive attention to detail, SH! It's a good feeling, watching stuff fit back together knowing that you can see progress on the down-side of the hill being made rather than having stuff progressing off-site somewhere else.

I would say "Keep up the good work" but I don't think there's any doubt lol

[Sid Squid]

Looking good!

Now get back to the shed and get on with it - I want to see it finished!

Great job. Again, looking forward to the final result. Not that we want you to rush!

[squirrel_hunter]

Now for some more attention to detail, the rear brake light assembly and number plate mudguard.



The original brake light wasn't very nice. It had been drilled for the LED from the alarm.



And even a spare I picked up with a mudguard and brackets wasn't up to scratch. I kept the brackets as these had been modified for the alarm, but that was all. So with the spares back unit and the originals wiring I cleaned it all up.



Then eBay unearthed a new lens cover so I had that for a bargain price. And stuck that on.



Fully assembled the brake light unit is as good as new.



So I married it up with the number plate mudguard I cleaned up earlier and some powder coated brackets (including one that I spent a little time bending back into line).



And stuck it on the bike. But not before I added a set of new indicators as the others had a few road related marks on them. Interestingly the indicators are different part numbers for the left and right, but the only difference is the colour of the wires which did make plugging them in a little easier.



And as for the detail, the tool kit retaining strap. The catches are a mixture of new and old Hammerited black. Just a shame I don't have the original tool kit.

[squirrel_hunter]

Rear wheel is now in.



But as usual there are one or two issues. Excluding the problem I have refitting the pillion footpegs to their hangers that I think I might have a solution to.



The first is the exposed metal on the sprocket carrier. At first I thought it was not in quite right, but comparison with a spare rear I can see it is.



The sprocket carrier was originally painted. But as I had it powder coated it was blasted back first. If I were to have had it coated I'm sure I would have had more fitment issues. I have thought of painting it, chuck a bit of Hammerite on it. But then that might give similar problems. So at the moment I'm thinking of leaving it. Besides once I get some miles on it I'm sure it will look like my spare with the lube fling.

Now for the other problem, the axel lock nut.



The wheel is in correctly but isn't torqued up as that will be done when the chain is on. But as you may be able to see the lock nut for the axel nut is not fully on the axel as you can see a totally clean thread ring in the lock nut which indicates its never before seen the light of day while in use.

Now I don't think that this will be a problem as once the main nut is tight it shouldn't go anywhere and its only out by 1 thread. But its going to be playing on my mind.

But why is it like that I wonder. I've checked all my photos and I don't have one that shows the original fitment of the axel nuts but presume that the lock nut was right at the end of axel. I'm thinking that the thread has been lost due to the additional width I've added due to the powder coat. Though thin it all adds up, there is powder on both sides of the swing arm inside and out, both faces of the chain adjustment guides, and powder on the caliper hanger bracket. Not much but it all adds up.

So my options as I see them are to shave a load of the powder coating off of various places. Find a thinner lock nut. Or to replace both axel nuts with a single locking nut like on my SV. I'm thinking of the latter option unless anyone can suggest otherwise?

You could get the main nut turned down a little on both sides, shouldn't affect the threads.
Once its fully torqued up it may be on further, and as you start to ride it you should be re-checking it anyway after the first few miles considering the work thats been done.

[squirrel_hunter]

Right, this update should have been quite good, with a nice bit of progress being made. However things did not go quite to plan.

But first a little good news. The tank bracket is on. Its taken a little longer than I expected as I needed to cable tie the mounting rubbers on. The trouble there was I couldn't find a cable thin enough to fit in the grove, but long enough to get all the way round. Eventually I tracked a bag of the right size down at my local Maplins.



I also slipped the flasher relay on an pugged it in. The cable appears a little tighter than I would have wanted so will have to see if its going to get in the way at all or if I need to give the loom a bit of a giggle once more of the bike is together.

But now the bad news. This post should have had the front brake assembly completed in it however after completely rebuilding the brakes it all came apart at the last stage. All I needed to do was to put the new bleed nipple in and as it tightened it ready for the fluid to be poured in I noticed that it wasn't tightening.

The bleed nipple thread has stripped.

This leaves me a bit of an issue as I need to get the pistons and seals out to use in my spare caliper, but as I can't fill this caliper how am I going to do this?

[Sid Squid]

If the thread on the nipple is OK, then a Helicoil or similar to repair the thread in caliper will be fine.

[Bibio]

just tap the nipple hole one size up and use a bigger nipple. if you have a compressor use a blow gun in the nipple hole and cover the banjo bolt hole with a finger to get the pistons out. or use a tyre pump with an airbed inflater. if the pistons have been serviced they will come out very easy.

looking goooood.