Thumper Club Forum
Technical => Project Progress => Topic started by: Steve Lake on March 06, 2019, 05:52:37 PM
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Well, i knew it was an mot failure when i got it, also not charging battery, failed on rear brake, disc was paper thin..... so clever clogs here thought .... i have the bits ... i have the info ... what can possibly go wrong ??
quite a bluddy lot by the looks of things.
i liked the look of this machine as it was virtually 100% original, just hagon shocks and braided hoses being the difference, my intention is to keep it as near original as possible.
so, following a close inspection, here's the list of issues so far ..... (there may be more to follow :-) )
rear disc, .all footrest rubbers crap or missing, ditto kickstart & rear brake rubbers. both forks leaking like a sieve over brake assemblies. bleed nipple on front caliper sheared off, ditto rear caliper. seat upholstery falling to bits. tank appears to have been painted with a tar brush, petrol barely flowing to carbs, throttle cable bell crank on side of carbs hanging off casting for fixing bolt sheared off.
not charging battery , wiring in a mess.
not feeling such a clever clogs now :( ..., progress report to follow ...
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Evening Steve, I assume the bike in question is an srx of some description??.... best of luck with it and yes keep us posted 👍👍🤘. Cheers, Michael
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sorry, yes... a 'D' reg SRX600 1JK (grey import).
addition to the list, front mudguard in complete tatters.
pic is sorry state of the front brakes, complete with fork oil contamination
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MMMmmmm! :-X
Have shirt! ;)
All the best, Bill
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"It'll be worth it in the end" " be lovely when it's finished " Put these sayings on a tape at the side of your bed Steve and play it on loop as you sleep. Bit of subliminal messaging, it'll work wonders 😉😉👍...
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Therapy, that's what'll sort it - of the talking variety, preferably in sessions down your local. However, with the amount of issues you have to cover, this might get expensive :-\ Let's hope the barmaid is a proper sort to make your medicine go down a whole lot smoother :o ;D
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got the electrics sorted,..... supposedly the generator had been changed, the regulator had been changed (for a non standard one, which i tested on my #6 srx, and it works fine), the battery had been replaced, (dunno why, if the original had been faulty there would have been no lights ??)
the wiring to the regulator was rubbish and included an adaptor to allow fitting of the non standard regulator. the 'new' battery was bone dry!!, surely they hadn't bought a dry charged battery and not added the acid ???...
cut out the crap wiring, fitted the correct plug to the new cabling to take a standard regulator, fitted a tested regulator, and a new battery.
fitted an additional earth from the heatsink to the chassis.(a silly habit of mine).
all works a treat now.
not the tidiest of jobs, ... function over form ;)
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This might all seem like an unseemly rush... but i've decided to have this job done and dusted by the end of the month, mot first week in april then flog it.
got the calipers back from my Mr Fixit, + a spare repaired as well.
the 2 gold ones are from the rear of #6 srx (i'd bu55ered one up last year, then did the same thing again a couple of weeks ago ... doh!)
the 2 grey ones are from #9. both were sheared, he got them out with heat and an easyout.
same for one of the gold ones, the other had to be drilled and tapped and an oversized nipple fitted. so i'll have them all fitted up and bled over the weekend.... well that's assuming rebuilding the forks goes according to plan.
not sure whether to replace the head bearings with taper/roller's .... will check them over the weekend.
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Aye Steve,
A celebratery Abbott appears in order! ;D
Northerly wind and hill snow up here today, after 36 hours of sleety wetness and easterly winds; the Duke is progressing slowly. ;)
Good health, Bill
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forks now fitted with new bushes, seals & clips.
i don't know what others use for stripping their forks, but this is my rather rudimentary (but effective) weapon of choice, just a bolt welded to a 1/2" extension, then used with another extension and 'T' bar.
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Nice work!
My fork stripping tool is even more rudimentary - a length of all thread with two nuts locked together at each end!
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Proper mechanics, you two. Having got a hobby welder for Xmas (opening here for rant on spelling ;D) I must copy your design, Steve.
But, I do have a pukka compression jig - a wooden stool with a hole in the top to accept the cap nut; the stool sits underneath battens fixed to the wall at the appropriate height to retain the stanchion by its mudguard lugs once the forks have been compressed.
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Now got the back end rebuilt, cleaned and stripped the swingarm, then repainted. rebuilt the caliper and fitted NOS disc, cleaned off wheel and regreased everything. hagon shocks, though filthy & rusty are in very good shape. ........ now we move to the front.
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Wowsers Steve that subliminal tape at the side of your bed must be getting some air time, given the rate of pace you're going 😁👍... looking forward to seeing the completed pics. Cheers, Michael
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At the moment i can't seem to upload pics, says something about 'upload folder is full, contact admin'.... dunno what that's about.
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Impressive! 👍👍👍
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Hmmmm, bit of a problem with the front calipers, well, one of them, following drilling out of the sheared bleed nipple, and rethreading, the new nipple will not seat properly, either the seat is damaged or the rethreading is not square to the seat...... bu55er .... double bu55er .... leaking fluid has messed up 4 hours work on prepping and painting of the replacement mudguard .... ahh well.... was all going a bit too smoothly ....
a weeks hols in cornwall to think about it ... will have a plan in place by next weekend (hopefully). any ideas gratefully considered....
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Just make sure you take the tape to Cornwall with you Steve and play it on loop 👍👍
Have a good one , cheers, Michael
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Doesn't sound like an easy one to spot, this, as I would imagine it only has to be slightly unseated for it to leak. Best of luck.
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having given it some thought overnight.... my fist plan is to make up a steel dowel pin just the right diameter to fit down into the caliper without damaging the thread, i'll grind the end to a point at the same angle as the nipple, then i'll use some fine valve grinding paste followed by astonish mixed with brasso and lap it in.... but it'll have to wait 'til next week now.... it'll either be fixed or f.....d....
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It would be a genius fix if it works. What about getting another nipple to sacrifice on grinding duty, instead of the dowel? You could shave off the threads and weld it onto the dowel?
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now THATS an excellent mkII, thanks, will do exactly that, it means the seat will be set at the right angle ....
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Aye Steve,
Go and chill! 8) Get the 'Doombar' in, with some good tasty fresh fish dishes, followed by something loaded with clotted cream and fruit! ;D Worrying about your end angle will do you no good! :-X
We have returned to sleet showers, with a cool nor'wester today, but I have still been out for an 80 mile fling and found a new to me, Italian cafe, with good Americano and chocolate fudge cake! ;) Not a word to my dear wife, I nicked the Bros for the run as well! :)
Happy paddling, Bill
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‘Ere Bill me ‘ andsome ... it’s a bottle of Bordeaux tonight, courtesy of the cottage owners... will start on the proper job & tribute tomorrow :)
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Aye Steve,
;D
Not really a fan of Bordeaux or Beujolly and then there is bordello! :o :-X Just make sure you don't collide with a bordillo after your imbibing , as that will put a dent in your rim ;) and we don't want that! ;)
Toodle pip
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plan 'A' seems to work a treat, repaired both calipers..... firstly got a drill bit , a snug fit into the nipple housing without damaging the thread, gently took out probably 20 thou of the seat, which left it looking good and even. then ground a stainless bolt shaft to a nice angled point approx the same as the nipple, ground the seat using it with fine valve paste, then Astonish paste, then brasso.....
hey presto, after the usual half hour pantomime we lovingly call ' bleedin srx brakes ' i got an excellent seal on the newly seated nipple.
this was for the rear brake on #6, the inner nipple had sheared a while back, and i'd used a bolt with a 'o' ring to seal it.... but mention was made of it at the last mot, and the brake was a bit spongy as obviously there was a bit of air left on that side.
brake is now really solid, well pleased with that. and i've sorted the weepy fuel tap with a service kit from M&P, also new pipes and filters.
just a few electric niggles to sort then #6 will be ready for MOT
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YES! ;D
Keep the stove on in the shed over the next few days and I'm sure you'll sort it.
Toodle pip, Bill
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i think you're right Bill, we're about to get a dose of your crap weather dahn sarf now, so stove on, and lots of bits i can be getting on with (like swmbo list of repairs :-) )
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You, Sir, are a motorcycle surgeon!
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all looking set fair on #6 & #8,
#6 has a leccy problem, which looks like a dodgy battery, so easily fixed, then MOT, hopefully for the weekend.
#8 is a bit of a bu55er , no sooner do i get one (or lots) thing done that summat else shows up. on close inspection the front tyre is showing signs of distress, cracking and uneven wear... so the plan here is to use the tyre off #1, (currently in bits on the bench awaiting me to finish gearbox repair), then, when (eventually) #1 is sorted, i can fit a nice new tyre to it.
then.... having sweated blood over the brakes on #8 and thinking all was now well sorted, i noticed brake fluid round the coupling on the r/h caliper, turns out the s/s pipe union is leaking (where the pipe is CRIMPED to the banjo, not a COMPRESSION nut sadly) so more expense :-\ , i'll probably replace both the front pipes, and get a new one for the rear .... you just can't be less than 100% with the braking system., i just can't wait to bleed all 3 brakes again :-[ :-[ :-[,
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Oh! Deep joy. :-X Bottle of Abbott, or two, required! ;)
Still awaiting parts at this end and foul weather. ::)
Warm Bramley hot cross bun and butter, with a Highland Park chaser afore sheet alley. ;)
Toodle pip, Bill
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light at the end of the tunnel..... #6 has a shiny new mot certificate with no advisories...
it was 3 miles to the mot station, i took the scenic route back home .... 42 miles of scratching norfolk roads ..... joy ;D
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You bin racing up tha drift bor! ;)
Heavy drizzle and low cloud, with an easterly that would do Yarmouth proud up here; back to the workshop and stove.
Good health, Bill
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yup, got stove warming up workshop so's i can finish spraying #8's tank, interspersed with garden work on an overcast and chilly day...
all good fun
have a good day Bill
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Aye Steve,
Finished rebuilding the Bros ignition, with alternative pulse coils and ECU from a breakers down Sarf. A real pain of a job as the petrol tank, seat, rear cowling, exhaust silencer and rear exhaust pipe all have to be dismantled before draining the oil and removing the clutch cover on the right-hand side of the motor, to get at the pulse coils. Threading the wires through the back of the frame and into the four pin plug in the main loom is nightmarish and does anybody on here know how to remove the rear exhaust pipe from the bike without first removing the engine from the frame? :-\ Lovely bike, but the design for ease of maintanence is >:( >:( >:( mad, mad!
However, with new iridium plugs and full choke, the wee beastie came to life on the first prod of the button, so I hope we have a few more miles from it. Up to 97,800 miles now! ;D
Heavy drizzle and raw noreaster here for much of the day, so the garden didn't get a look-in, but managed a 3 mile walk, at pace, to keep the blood circulating! ;)
Hope there isn't any 'orange peel' on the tank.
Good health, Bill
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3 mile walk!!... sounds a bit energetic to me lol.... but reminds me i really should be getting out on my (push)bike a bit....
that Bros sounds a nightmare!.... hope it rewards you with plenty of reliable miles now..... still... it doesn't exactly owe you anything with nearly 100k on the clock :).
tank is going well, did get slight crazing on what was supposed to be the final coat (before the lacquer), so rubbed it out with 2000 dry and one more coat seems to have done the trick, will get workshop warmed up this morning and get 3 coats of lacquer on it, and hopefully job done. full tribe in attendance this afternoon, so that will bring fettling to an abrupt halt and bring into play table extensions, wine cooling, beer selection, setting places for 11 & general house keeping duties.... and woe betide me if i havn't got the aga up to the right temperature for what appears to be an ostrich ... (i'm sure swmbo'd ordered a turkey :) )...
weather crap here, can't see the end of the garden, and cold with it...
hope your day is a goodun Bill
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Good to have a "Tribe" to stir up the rut, we don't have a 'Tribe', but the Weeun keeps us on our toes nonetheless! ;)
More oak, holly, beech, ash for the Aga, the latter will be in plentiful supply at present due to the chalara. I am likely to be decking the ash around my place, as they are riddled with chalara and dropping branches in the slightest of breezes. :(
I'll raise an Abbott to you all!
Good health, Bill
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indeed, the ash round here is suffering... but... touch wood, most of my ash is still unaffected.... i'm guessing it will be though.... in fact, if it isn't the 'experts' will be round taking cuttings to replenish the uk stock with disease resistant varieties. .... hey!.... is there a business opportunity here ?
just completed 3rd coat of lacquer on the tank. will let it harden for a few days before i start the refitting process.
today the beer menu will include ... abbot reserve, old crafty hen, shepherd neame 1698, shepherd neame IPA, greene king IPA reserve .... not sure what the rest are having ;D ...
with 2 grandkids now over 18.... i'm having trouble keeping any ale stocks atall!.
pip pip
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A veritable feast of good ale! "Old Crafty Hen"? Got proper caught out by the strength of that at home one New Year's Eve and ended up on the couch! :P
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yes,,,, absolutely first class falling down water ;D
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On the last lap.... having resolved all the niggles on #8, which included having the poxy carbs being taken off/on 5 times before i could stop them flooding (ended up lapping in a new seat on the needle valve (unobtaneum) ... ). also tap leaked, so service kit fitted to that (3rd attempt at getting the right one from M&P).
thought i'd treat it to a new iridium plug ... sodding thing wouldn't start ... put old plug back in ... carbs off/on (AGAIN !) bingo. .. she lives ! ;D , seems to only need half choke from cold, so some adjustment required there ...
full pre flight checks carried out ... and a round the block ride as a shakedown .... all seems good so far except the front tyre is absolute sh*te ... goes round corners like a threpenny bit (if you don't know what that is, then you're far too young to be reading this sort of material) ...
local tyre depot (who pride themselves in supplying ANY tyre for bike or car or van or lawn mower) .. reckoned i must be mistaken ,,,, a 100/80 - R18 just doesn't exist ... bunch of tossers!, so i got on his PC, and showed him yamaha spec for the srx ...... 'oh' he says ... 'hang on, i'll call bridgestone' ... 'we can get one, special delivery .. 2 week lead time' ... shan't be going there again ....
oh... message for Bill .. 2 things i've noted about these (bluddy) carbs ...
1. item 42 in fowlers exploded view of the carb is called 'pilot screw set' . it's a spring loaded needle .... no information about haw far it is screwed in , i have 2 spare units here, one was backed off from fully home 1.5 turns, the other 2.5 turns, so at present i have #8's set to 2 turns.
2. item 43 on fowlers pic (the needle valve set) ... when i removed this from #8's carb, on top was fitted the tinyist filter, about 8mm dia clipped on... not seen this on any of the other standard carbs i've stripped ... maybe left off, 'cos once blocked with crud it's going to be a 2 hour job to get it cleaned.
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Aye Steve,
Apologies for the delay in ops. :-[ Inner Hebrides for a week at short notice (cheap) at the end of a cart track, beach 50yds away and a grand view of the rest of the islands, whilst reading books and watching sea eagles amongst other creatures doing their thing. Some ales were partaken as well. ;) Peaceful bliss, with a red nose and ruddy complexion from wind/sun!
Will investigate Sally, as she is dock at present, to ascertain carb settings and gauze filters. Report back on findings. I would rather leave the Mono alone, as it is the XT600E motor, but could investigate notes of rebuild. Again, will report back.
As for 100/80 x18 front tyre, I find the Avon Road Rider is fine and readily available at reasonable price. However, if Bridgestone is your preference then I would advise that you contact this outfit: Bridgestone_100/80x18_front_tyre (https://www.moto-tyres.co.uk/cgi-bin/rshop.pl?s_p=Bridgestone-BT45-F-100_80-18-TL-53H-M_C_-Front-wheel&details=Ordern&typ=76035&cart_id=L2cooQvNlgJKLzF2.1110.284287143&ranzahl=1&Breite=100&Quer=80&Felge=18&weiter=0&Ang_pro_Seite=10&dsco=1110&Cookie=froogle&m_s=1) Service has always been good when I have used them for wee diddy tyres for 125's that the local dealers blanch at! ;)
The 450 is progressing and I now have Belgian CDI ignition to fit instead of points. (Fettling required!) Lumpy cam and the 32mm Amal MKI on extended inlet, with gutted Goldie. Best part of 18 years since it last ran! ;)
Slainte, Bill