EN 125 overhaul

[nathanwhite]

Well, I picked up an EN125 today, for the very reasonable price of $0.00. A mate wanted it off his lawn and I offered to take it off his hands. :woohoo:

As it's been sitting on outside for god knows how long most parts are rusted or corroded.
My plan is to pull it to pieces, fix/repair what I can and replace what is too far gone. Once its back to optimal condition, I could turn it into a bucket, or cafe or even sell it ..... Meh, dont have to decide yet.

First arriving at home
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Damage on the forks
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Rusty shocks
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Cracked bodywork
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The only key to the bike
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Mirror stalks rusted out also
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Ducttape repairs on the indicators
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[nathanwhite]

So after snapping the pics, it was time to see what worked.
Stuck in the key and pushed the starter.....nothing.

After sticking a multimeter on the battery and getting a whopping 8.4V I pulled the battery and replaced it with the good one from my scorpio
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and it started up first time!
Then died.

I started it a couple of times and it idled fine. Gave it any throttle however and it promply died. Gonna see what thats about later.

Plonked the battery on a charger and left it to do its thing
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Now that I know its runs I started the teardown
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My high tech fuel draining setup
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Pulling out the undertray (?) I ran into problems getting the taillight and indicators out. After about half and hour of pushing poking prodding and unscrewing I eventually discovered further back a connector that popped it right out:facepalm:
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Remembering something I read somewhere to get the left grip off, I squirted some WD40 up it, left it for a while, then a little more wd40, worked it and off it came without any problems.
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When getting the wiring harness off I found this little tenant
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The spider was about 4cm long and didnt take to wd40 very well :innocent:

Getting the header off took about 45 minutes and was the most irritating thing to get out.
The bottom screw, torqued down rather well and also very rusted, but more then that was a pain in the @$$ to get to because it was in the small gap between the header and the frame.
Liberal use of the wd40, shock treatment and patience finally saw it out though.
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So at the end of day one, everything is out except the engine, the chain, a few bits on the frame and the front brake system.
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Comments/Criticisms and suggestions most welcome.
Let me know if i'm doing something wrong because the whole point point of this project is for me to learn stuff about bikes.

[nathanwhite]

Day 2

Started by pulling out the front brake system
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and it has a surprisingly decent amound of pad left
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Draining the brake fluid found a horrible gunky mess in place of the brake fluid
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I spend an hour (judging by the amount of songs played) trying to get the calipers off, but to no avail. I think i'm going to have to drill them

Then on to the chain
Took it off and stuck it in a petrol bath
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after a couple of hours and some fierce scrubbing with a toothbrush I ended up with
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With rust like this am I going to have to get a new chain?
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while for help with pulling the engine, I wire wheeled the mirrors
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and then finally got the engine pulled.
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Tomorrow I'm going to get it down to the bare frame and then start fixing it all.

[ducatilover]

Neat project dude. :Punk:

As for the bike dying when you give it throttle, clean the carb and re-set the float to factory specs, you probably have poo or alien spunk in the low speed jet.

[Ender EnZed]

Comments/Criticisms and suggestions most welcome.

Looks just about mint to me.

Give the carbs a good clean and charge the battery up. If you can get it going then she's good to go. :niceone: Ride it round till you find something really wrong with it!

[nathanwhite]

Alright got back into it today.

First things first, off with the rear wheel.
No problems there
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Then I moved onto the front end, loosing the tops of the forks before I undid the pinch bolts
Partially undid the top nut of the fork and was greeted with this lovely sight
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It was about this time I started to smell the old fork oil :sick:


Nevertheless I pushed on, suspending the bike and wiggling out the forks. There was a pointless cover on the lower triple which made getting the bolt loose interesting
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After it was loose I realized that I could have gone in from underneath. There was much more space to maneuver down there :yes:

Anyway, out with the triple clamp (tree?) and as the lower came out all the balls from both bearings dropped out and scattered across the floor. I think I found them all, but I guess ill find out when i'm putting it back together :facepalm:
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After a short break I took a wire wheel to the front brake rotor to clean it up
Sorry for the blurry pic, I didnt want to fiddle with the camera too much with greasy hands
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Now do I have to get the rotor machined down a 1-2mm to get rid of the rust pitting, or is it ok?
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Also wire wheeled the headlight brackets, all the way down to the metal, will either paint or seal it later
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I then turned my attention to the forks, and found that under that top cap was another seal, this one requiring an allen key of a size I didnt have :angry:

So Ill leave that till I have the right size tool.



One more question though, what can be done to fix the rust damage to the fork tubes? send to a shop to strip and re-chrome? chrome overtop? just get new tubes?
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[nathanwhite]

When I finally get the forks open, is there anything I should be aware about? springs under pressure etc (seeing as I have never done this before)

[ducatilover]

Springs are under pressure, make sure you put everything back in right order :bleh:
Send pictures to someone who does re-chroming, but a set of pre '04 GN forks will do it (pre-Chinese ones) I think.

Measure the bearings up and go buy new ones from a bearing stockist, it'll be cheaper than 'Zuki. :yes:

I'd definitely ride that little beast around town

Download an owners manual too

[nathanwhite]

More work done today

Cleaned up the engine

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Hauled the frame, swingarm and stands outside and busted out my $5 can of degreaser

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Once that was done, I attacked the frame with a wire wheel and scouring pad. Some elbow (and knee) grease later, the rust was gone along with the powder coating in affected areas. Covered it with CRC zinc paint and left to dry/harden
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On a side note I noticed recently that the front brake on my scorpio gets to about 3/4 of its braking power and doesnt brake any harder. I pulled the calipers off and noticed that only the smaller caliper was moving

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But then if I push it in, or hold it while pulling the lever, the other one goes

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I'm assuming this is not normal, but I have no idea if its the problem.
Any ideas?

[Henk]

The one pot moving when you haul on the brakes with the caliper off is quite normal. As long as they both move things are pretty fine from that point of view.
First thing I'd be looking at if the brakes haven't been bled for a while is fluid, the fact that both pots move indicates that the caliper is largely OK.

[nathanwhite]

The brakes haven't been bled for some 10,000k ie since new, so yea maybe its that. Ill bleed it tomorrow (or soon anyway) and see what happens.

Thanks

[Grant`]

Good work dude, looks like a nice little project!

[nathanwhite]

I just went out to that garage to grab stuff and saw this

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Lovely patch of dead grass outside
In hindsight, it may have been agood idea to do the degreasing on the driveway
:facepalm:

[ducatilover]

Great progress dude.

My 5C:
Powdercoat that frame, or hammerrite it. Will look great and be tough as a women with a heavy handbag.

Polish the covers on your motor, those small touches make such a difference :yes:
I painted my motor gloss black and polished all the covers by hand (don't go that far, it sucks) and it looks a million bucks.

[nathanwhite]

Ok, an update.

Done a few bits and bobs, but the main thing is I finally got my plan of attack sorted.
I'm going to clean/fix/sort out stuff as I rebuild the bike. I had a vague idea of doing it all before as a seperate stage, but I think this will be easier.

Cleaned up the wheels
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After
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Took a scouring pad to the shocks

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Put the stands back on
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Pulled apart the speed sensor, more to satisfy my curiosity then because it needed it. Degreased it and now its waiting for when I rebuild the front to get put back together

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Got one of the forks partially apart

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Spring out

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Dust cover off

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Lovely rusty crap on the inside

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Now does anyone have any idea how I would get the rear shocks apart? googleing hasn't produced any helpful answers and I cant see anything to be loosened/undone/whatever to get them apart
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I've also hit a snag in getting the other fork open, the top nut totally refuses to turn no matter what I do to it. I suppose the main problem is it the hex head/nut thing stripped and I dont have the next size up

I tried making a grove with a rather large screwdriver, but haven't had any luck there
bah, Ill keep trying tomorrow.

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[nathanwhite]

Perhaps instead of fixing the shocks I could nab some off trademe.

http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/suspension/auction-444966119.htm

any thoughts?

[Maha]

Great project ya got going there Dougie!:niceone:

[ducatilover]

Perhaps instead of fixing the shocks I could nab some off trademe.

http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/suspension/auction-444966119.htm

any thoughts?
If they fit, why not? They look much cooler than standard

[Henk]

Your shocks are not rebuild able and if you get them to bits chances are they'll never go back together again. Not sure that I'd be spending money on the cheap ones off TM either, they are probably no better than the ones you have now.

[geoffm]

Don't bother with the balls in the steering head bearings - get some tapered roller bearinds and put new steering head bearings in. Be a big improvement.
New rear shocks (even cheapies) wil be a big improvement.
The forks can be rechromed, but that does cost money. A budget way until you can find replacements or rechroming is to rub down the rusty bits,and fill with epoxy, once dry snad off with very fine emery paper until the pits match the forks.

Be a good commuter once it is finished.

[shafty]

Good effort Mate - will follow with interest.....

[nathanwhite]

Not sure that I'd be spending money on the cheap ones off TM either, they are probably no better than the ones you have now.



New rear shocks (even cheapies) wil be a big improvement.


:scratch: erm.... right.

Well, I got the hundred dollar ones of trademe, ill try both of them when the bike is back together

[nathanwhite]

Alrighty! got some more work done today (I have plenty of free time atm because uni hasn't started I suspect it will be a different story in a week)

Issues with that fork notwithstanding I have decided to start rebuilding as much as I can whilst sorting out the fork, rather then focusing on it and driving myself insane. That said I do have a thought for it, a little more on that later

Greased up the lower half of the bottom steering head race
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG016.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG016.jpg" border="0" alt="Photobucket"></a>


And then cleaned and installed the balls one at a time
(can you say, tedious, boys and girls?)

Anyway with that done I greased the top half of the race and installed the lower triple in.
Then realized that maybe it would be a good idea to install the top bearing before I screwed it down.



So grease
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG019.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG019.jpg" border="0" alt="Photobucket"></a>

Balls

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG020.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG020.jpg" border="0" alt="Photobucket"></a>

Installed

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG021.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG021.jpg" border="0" alt="Photobucket"></a>

And cleaned up

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG022.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG022.jpg" border="0" alt="Photobucket"></a>

Lower triple in

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG023.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG023.jpg" border="0" alt="Photobucket"></a>

Onto the top triple!

The two screws that held the ignition in were done up so tight that after a full five minutes of trying I gave up and cleaned it with it still attached

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG024.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG024.jpg" border="0" alt="Photobucket"></a>
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG025.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG025.jpg" border="0" alt="Photobucket"></a>
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG026.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG026.jpg" border="0" alt="Photobucket"></a>
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG027.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG027.jpg" border="0" alt="Photobucket"></a>

Plonked it on the steering head and torqued it down to the recommended factory setting of "rather tight" by the highly accurate fingerometer

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG028.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG028.jpg" border="0" alt="Photobucket"></a>

Checked that it couldnt move independantly of the lower triple but didnt affect steering movement and I was done.

[nathanwhite]

So my idea with the forks is to drill out this little doohickey that is holding all the other innards in

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG030.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG030.jpg" border="0" alt="Photobucket"></a>
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG031.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG031.jpg" border="0" alt="Photobucket"></a>


Right now conventional wisdom is screaming at me to rebuild the other fork and be done with it.
However I have a new set of fork seals on order and I dont want to have one fork with a new seal and oil (or just oil) and one old.

So if I can drill it out without (hopefully) damaging the other internal components then get a machinist to make up another one based on the one pictured from the other fork.


oh and my dad says he has some easy outs which we will try on the weekend

But then we drill!! :eek:

[nathanwhite]

Made some progress, infact, quite a lot of progress.

Cleaned and stuck on the swingarm

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG033.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG033.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG034.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG034.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG035.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG035.jpg" border="0" alt="Photobucket"></a>

The frame design is a little irritating, one of the main engine bolts is also the swingarm bolt.
So thats going to have to come off again when the engine is going back in

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG036.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG036.jpg" border="0" alt="Photobucket"></a>

Put the old shocks back in while i'm waiting for the new ones to arrive

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG037.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG037.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG038.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG038.jpg" border="0" alt="Photobucket"></a>

And wouldn't you know it, the very next day!

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG039.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG039.jpg" border="0" alt="Photobucket"></a>

Now they are a little longer, but thats not really an issue, what is however is the bottom connector.
To get it to fit i'm going to have to drill it oversize and there is not a lot of metal left on the bottom

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG041.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG041.jpg" border="0" alt="Photobucket"></a>

But anyway, rear wheel and sprocket on

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG042.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG042.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG043.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG043.jpg" border="0" alt="Photobucket"></a>

Finally managed to (partially) get the brake caliper open. Still not completely there but closeish
The bit pictured is apart that was just for dramatic purposes
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG044.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG044.jpg" border="0" alt="Photobucket"></a>

Drilled out the fork cap thing which wasn't nearly as hard or long as I thougt it was going to be.
Turns out the reason it was stuck was because some dipstick screwed it on waay to far, past where the thread ended.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG045.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG045.jpg" border="0" alt="Photobucket"></a>

All out
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG046.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG046.jpg" border="0" alt="Photobucket"></a>

due to the (also irritating) design of the inner fork tubes, they came straight out and to get the fork seals out I had to spend about half an hour pulling, poking, prodding and snipping with pliers and wire cutters to get them out

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG047.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG047.jpg" border="0" alt="Photobucket"></a>

and the other one

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG048.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG048.jpg" border="0" alt="Photobucket"></a>



Now for a funny (and facepalmish) moment. I bought some metal epoxy to try on the fork tubes

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG049.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG049.jpg" border="0" alt="Photobucket"></a>

Once I had a fair amount of it on and it had hardened for almost the specified time, I found that getting it thin enough to cover the pitting but not to come off completely was damn near impossible

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG050.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG050.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG051.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG051.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG052.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG052.jpg" border="0" alt="Photobucket"></a>

Then i realized that I hadn't stripped the pitted sections all the way down to the metal

<<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG053.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG053.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG054.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG054.jpg" border="0" alt="Photobucket"></a>

:facepalm:

Wirewheeled all the pitted sections down and then called it a day

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG055.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG055.jpg" border="0" alt="Photobucket"></a>

[mossy1200]

:scratch: erm.... right.

Well, I got the hundred dollar ones of trademe, ill try both of them when the bike is back together


I got my trailer shock from same guy.Seems to work ok but its only on a trailer so prob not the best way to test them for performance.


http://www.youtube.com/watch?v=aGsol9_kY28&feature=g-upl&context=G259b9a6AUAAAAAAABAA

[nathanwhite]

Wow! thats a very nifty little thing

Does it change the handling much and/or do you have to take special considerations with it?

[nathanwhite]

I tried the putty epoxy again today. Same result funnily enough.

It did work a lot better this time because a) I could apply it thiner b)I took my time sanding it down (who knew it could make things better? :bleh:)

But still it came off where I didnt want it too and still was a horrible grey colour that I would have had to cover up with a tacky chrome paint or something.

Gonna give some clear jb weld a try. The shiny bare metal in the pits doesn't look too dissimilar to the chrome plating so clear should be good.

[ducatilover]

I'd drill that shock hole out to, say 8-10mm and then sleeve down the hole on the swing arm. :niceone:

[nathanwhite]

After thinking things through very carefully -tui ad there- I wondered if I could get the top off the original shocks and stick them on the bottom of the new ones (or the top?)
A bit of fiddling later I managed to get the trademe shocks apart too see how they work. Turns out the problem section and the spring holder-on-thing just screwed into the damper rod. Very nice.
Onto the origional shocks and a bit more time spent fiddling and trying various things, then I finally managed to get them apart!

:eek: :first: :Punk: :wings: and so on

it took me, my dad and the, tie-a-million-cable-ties-on-while-at-full-preload method to get it off but its off.


After a lengthy intelligent discussion about the various ways to machine the pieces to fit together, I realized that now that it was apart, why not clean it up and reuse it?
SO I think that's what I'll do. It'll be easier then retrofitting other shocks to fit and the spring/damping rates will stay the same.



Sorry no pics, I CBF'd going through the process of getting them online for only two photos. I'll stick them in the next update

[FROSTY]

good onya with the project .
a heads up. Those lil engines are fairly cold blooded anyway but stripping and cleaning out the carby completely will really help the idle issue.
With the front forks I would clean up all the sharp edges of rust then try clear 2 pot epoxy one pit at a time. It needs to be about 1.0mm thick Once dried tou can sand it smooth with 1500 grit. used wet. you might get em working fine that way but not pretty so try a set of fork gaiters. They dont look strange at all once back together

[nathanwhite]

small update with the fork legs.

(i think i had some other photos that needed posting but they seem to have got lost after the taupo trip <_< )

Anyway.

Stuck on the clear epoxy, must say it looks a lot nicer right off the bat.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG001-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG001-1.jpg" border="0" alt="Photobucket"></a>

Then wet sanded it down with 400 grit, which was all i have right now

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG004-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG004-1.jpg" border="0" alt="Photobucket"></a>

Seems to have worked ok. I like it anyway, I'll just stick some boots (gaiters?) ontop of them.


On another note, I started stripping down the spring of the one shock i have apart (pending me getting more cable ties to get the other one done.) Discovered quite quickly however that its a little hard to get inside the spring with a wire wheel. So i'm also going to have to get a paint stripper of some description. Something that doesn't make springs brittle, which i'm told is a danger when applying those types of chemicals to springs.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG002-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG002-1.jpg" border="0" alt="Photobucket"></a>

[nathanwhite]

Small amount of progress made, I got some emery paper and used that to sand the inside of the spring thus getting rid of the rust on the inside :wings:

After half an hour of sanding I have a nice and shiny spring!
257907

Now to start on the other shock.

[nathanwhite]

Moar progress!

Got the other shock off the bike and pulled it apart

Setting preload to max and a zillion sticking cable-ties on it.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG057.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG057.jpg" border="0" alt="Photobucket"></a>

Backed off the preload wedged a spanner in there and twisted

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG058.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG058.jpg" border="0" alt="Photobucket"></a>

And just like that it's off

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG059.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG059.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG060.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG060.jpg" border="0" alt="Photobucket"></a>


Stripped the spring in the same manner as the other one and then covered them in primer

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG062.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG062.jpg" border="0" alt="Photobucket"></a>

It was a little interesting spray painting a spring, the inside was just as hard putting stuff on as it was taking stuff off. So I ended up giving it multiple very very light mist coats to build it up as evenly as possible. Despite my efforts however the coat on the inside is not a thick as that on the outside and I doubt will be unless I dunk it in paint. However it is fully covered and ill give it another couple of coats tomorrow and that will do.


As a time filler while I was waiting for the paint to dry I cleaned up the rest of the shock

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG063.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG063.jpg" border="0" alt="Photobucket"></a>
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG064.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG064.jpg" border="0" alt="Photobucket"></a>

[nathanwhite]

Alrighty got the rear shocks finished and back on :banana:
progress pics for ya.

This is my genuis rig to re-compress the springs seeing as I didn't have any of this "proper equipment"

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG065.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG065.jpg" border="0" alt="Photobucket"></a>

Stuck a mass of cable ties on and did them up super tight

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG066.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG066.jpg" border="0" alt="Photobucket"></a>

then pulled the spring off, stuck it back on the shock and wedged a spanner in there to tighten the top thingy off.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG067.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG067.jpg" border="0" alt="Photobucket"></a>

(getting it out was a pain though. Took me about half an hour)


TA-DA! one assembled shock

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG068.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG068.jpg" border="0" alt="Photobucket"></a>

What I did notice was that that paint wasn't fully hard yet and the cable ties left little marks on the springs. Too bad though i'm not pulling them apart again!

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG069.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG069.jpg" border="0" alt="Photobucket"></a>

[ducatilover]

Looking good mate, nothing like attention to detail!

[nathanwhite]

Looking good mate, nothing like attention to detail!

makes all the difference eh?

[ducatilover]

makes all the difference eh?

Too right, I can't stand people putting something together with shitty parts hanging out.
I'm a bit mad though :devil2:

[nathanwhite]

ITS BAAACKK!!

Righty, after a lengthy wait I finally have that little piece sorted that stalled the whole build.

It was a little cappy type thing that held all the guts of the fork inside and well.... No forks = no front wheel = no engine = frame sitting in the garage waiting for something to happen.

But anyway. Dad said he could rebuild the piece for free at the machine shop of the polytech he works at. Weeks later and nothing has happened so I'm chasing him up. Another coupla weeks and he finally has the piece, but it doesnt fit! :facepalm: Not his fault though, the pitch of the thread is something like 1.013mm. It's enough that the new piece (with a 1mm pitch) doesn't work.

So a new plan is hatched.

Instead of the cappy thing, put in a spacer and let the top cap hold the fork internals together.

This is what we came up with:
Left, spacer. Right, actual piece from other fork.
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7368.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7368.jpg" border="0" alt="Photobucket"></a>

With that done, I charged ahead rebuilding the forks with nary a thought if I was doing it correctly

Fork seal in
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7369.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7369.jpg" border="0" alt="Photobucket"></a>

Dust cover on
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Tube in and damper rod installed leads to a almost completed fork :woohoo:
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After some careful measuring, the spacer didn't quite go down as far as the cap would have, So I had to break the threadlock and stick an extra washer on
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7373.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7373.jpg" border="0" alt="Photobucket"></a>

Then putting it in the fork, realized that the new washer was too large to fit past the internal thread :facepalm::facepalm:

So I had to spend half an hour or so carefully grinding and filing it down to size
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7374.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7374.jpg" border="0" alt="Photobucket"></a>

But it all worked nicely in the end, so i'm very happy. The forks are assembled and ready to be chucked back on the bike. I (finally) found a service manual for the bike (en español.) I have fork boots coming, which is why they are not on the bike yet and this weekend I should have it almost completed!

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I'm still not totally happy with the clear epoxy over the pitting in the tube. I think I may even just ge rid of it all and polish the whole thing with incrementally finer grades of steel wool and leave it with boots on.

[nathanwhite]

Mailman came!

Boots will be on later this afternoon and forks will be on the bike also.

:woohoo: Progress feels good!

261789

[ducatilover]

Good stuff dude, I love it when the mail man comes! (he's gonna be seeing me a lot over the next month:D)

[nathanwhite]

Good stuff dude, I love it when the mail man comes! (he's gonna be seeing me a lot over the next month:D)

How much more new stuff have you got to get?

[ducatilover]

How much more new stuff have you got to get?

Not a heap.
Fork rebuild kit.
Oil filters.
Lots of assorted fittings/lights etc, all been ordered.

Few other bits and bobs

[nathanwhite]

Small problem that I anticipated was the boots not fitting quite correctly.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG001-2.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG001-2.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG002-2.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG002-2.jpg" border="0" alt="Photobucket"></a>

Nothing much about this bike is usual it seems, always odd sizes and shapes. Makes it a little hard to get parts and stuff :mad: In this case it the fork stanchions were 30mm and the top of the bottom fork thingys were 50mm. The boots I got were 32mm and 52mm respectively.

However that particular problem was easily solved with cable ties, and then it was onto putting the forks back on the bike!

Regreased the speedo unit. I didn't how much was actually needed, so I just put it every where
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG003-2.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG003-2.jpg" border="0" alt="Photobucket"></a>



Then it was line everything up and stick the axle in and

VOILA



oh wait, no not just yet.....

Had to clean up the bolts holding the brake rotor in (and show the obligatory pic of before/after)
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG004-2.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG004-2.jpg" border="0" alt="Photobucket"></a>

The pictures don't really do it justice, they come out really nice and shiny. :D


When that was all together,

VOILA

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG005-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG005-1.jpg" border="0" alt="Photobucket"></a>

rolling chassis. Ready for engine in and general rebuild tomorrow. :banana:

[Maha]

You should remove that key Dougle...it has the potential of being snapped off in the barrel all exposed like that...:cool:
But...looking good, you have much to be proud of here.

[ducatilover]

:cool: Epic progress

[nathanwhite]

Righty. Plowed into it today like a locomotive on crack.

My goal was to get the bike running. This was no mean feat starting from a frame, but I like challenges.




Started off by trying to clean the carb a bit, it looked quite groddy.

(note, this is a before pic)
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Motor in :woohoo:

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Handlebars on in prep for dummy rigging of controls to get wiring sorted. Note there is now no key in the ignition...
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New breather and overflow (I think thats what they are) pipes for the carb. The old ones wern't too badly gummed up, but they were discoloured and looked horrible. So new ones it was.
I didn't get the carb looking particularly nice, but i'll have at it again later.
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG004-3.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG004-3.jpg" border="0" alt="Photobucket"></a>

Wiring loom just about to go on.

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Exhaust in place. I'm going to take it off again and clean it when I get the bike running.
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<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG007-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG007-1.jpg" border="0" alt="Photobucket"></a>
^look at that header :shit: :sick:

Wiring Loom about half installed. It was at about this time I realized the value of taking a whole lot of reference photos before so You know what to plug into where. I had about half what I needed

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I realized just a little after that pic that I had a service manual sitting on the computer at home. Suddenly full of hope I checked it and it had a circuit diagram!! That was in english!!

So got the rest of the wiring loom finished in reletively short order after that.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG010-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG010-1.jpg" border="0" alt="Photobucket"></a>


I plugged in the battery, assembled the throttle line, rigged a makeshift fuel line, checked the engine was in neutral, turned it on and pushed the starter...........nothing. Huh.


After about half an hour of poking various things with a multimeter and ruling out different causes (had a scary moment when I thought it was a broken wire) I took a close look at the starter relay and realized that I hadn't plugged the control wire into the right place! Fixed that and she cranked!!!


and cranked and cranked and cranked .....


ok. Not starting.



Most likely at fault is a gunked carb, seeing as this bike was sitting for quite a while. So I pulled it off and apart

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG011-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG011-1.jpg" border="0" alt="Photobucket"></a>

Taking note of the various bits and where they went as I was going. (never done this before y'see)
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and left the various needles and jets soaking in what supercheap auto told me was carb cleaner.



Now this little bit came out the bottom (I think) and I have no idea where exactly it's from. Does anyone know what it is? or even could be?

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[ducatilover]

You sure that fellow popped out the bottom? Could be a diaphragm needle seat?
I'm sure you'll find where it goes.

Brilliant progress man!
I can now do a motor in/out of my ZZR600 in 3 hours flat :D

[nzspokes]

Its the needle seat, goes in above the emulsion tube that the main jet goes into. The tapered end goes towards the needle.

[nathanwhite]

Its the needle seat, goes in above the emulsion tube that the main jet goes into. The tapered end goes towards the needle.

ah thank you.

[nzspokes]

ah thank you.

Go to the Motoone nz site and on the front page is the parts monster link. Find your bike on there and you can find diargrams of the carb.

[nathanwhite]

I got it running!!!!:woohoo::woohoo::woohoo::woohoo::woohoo ::woohoo:

although....
after pulling the carby apart for the 5th time I finally worked out that the float needle was working just fine thank you and that all the fuel pouring out the bottom was simply the drain screw left open.
So then if it wasn't the carb, what was it? One other likely culprit....
Pulled off and tested the spark plug...ah. No spark.

I then looked up at the spark plug relay/coil/transformer/powerup/dont touch it thing and found that it wasn't plugged in. :facepalm::facepalm::facepalm:

She needed the teensiest bit of coaxing to start, but once it was going.......



So yes, I'm happy now

[nathanwhite]

Coupla minor things I got sorted, the chain lifter assembled to the swing arm and silly me hadn't put it on when putting the engine in. :mad: So swingarm bolt out again, bit of wiggling to get it all in place and tried to put the bolt back though......not happening.

Eventually it took two of us 10 whole minutes to put the $%@#* bolt into place (after i'd struggled with it for about half an hour) had to hit it with a hammer to get it in...naughty I know but hey it worked.

So finally in:

262481

Also put the footpegs back on, seemed like a innane small thing that was better done when I could rather then sometime in the misty future

262483


Chains arrived, yes both of them. Silly me bid on one then saw a better offer on and bought that one thinking/hoping that I wouldn't win the first. But I did.
It's not a huge issue though, becuase its the same size chain as my scorpio, so I have a spare now :cool:
262484

[nathanwhite]

Now I shouldn't go any further before sending a huge thank you to Mom and Maha.
They had this very nice digital calliper that they weren't using and just gave to me out of the blue.

:gob::gob::gob:

They are much appreciated and will come in very handy

262486


you guys rock. Seriously. :headbang:

[nathanwhite]

Now that this bike is going and stuff is happening I'm starting to seriously think about where this bike is headed. The way I see it, I have three options.

1) Simply rebuild it and get it made roadworthy. Then sell it off and make some $$$ out of it. Nothing else
2) Mod it. Bogan's post of an EN of GingerMidget's thread got me pretty inspired. Then either sell it or keep it, depending on whats happening then
3) Turn it into a bucket. It would be a blast i'm sure, and quite a cheap way to get into it.

Getting it roadworthy will mean (on top of other things) getting it re-rego'd. This will cost more then what I have spent on it so far and I have no idea whether or not it will need re-vinning too, which would add a quite a bit.

I may be speaking out of naivety here, but I think turning it into a mini-cafe or similar style bike wouldn't be too expensive, and definately very fun. The downside of this is after all that, I would most likely still have to get it roadworthy in order to move it on which raises all the previous points negatives.

Bucketing it, would remove the costs of getting it rego'd/vinned again. I would get to do most of what I would do for the mini-cafe thing, but without having to make it super perfect, which takes up a lot of time and effort. There's something very cool about getting to turn a standard bike into a race machine, even if it is only 125cc.
The only significant costs I can see with this is getting gear for the track. I'm know I can borrow a trailer/car or find someone to help transport so that shouldn't be too much of an issue.




hmmm......

[ducatilover]

I vote you go cafe racer with it

[GSW]

I vote you go cafe racer with it


+1 for this idea.. and you're doing an awesome job !!!

[nathanwhite]

Photobuckets being a pain for me so no nice embedded photos, attachments only :(

:cry:

ok todays efforts

First thing I attacked was the horrible gunky exhaust and header. I had a funny moment a while back when I cleaned the header of my scorpio with WD-40. Got off a short ride and thought I smelt something burning. Looked down and saw my header smoking :shit:. Then I realized that wd-40 is a light oil type substance. Which burns. :rolleyes: However I proceeded to clean this pipe with it because I know its damn good at getting rid of piled up gunk.

Before...262623

after about 10min with wd-40 and a scouring pad......262624

Then I brought out the big guns, or gun actually in the form of a wire wheel...262625
262626

Now with the end looking so bad, and I think the rust goes a fair way into the pipe, am I going to have to replace the exhaust? I hope not, but hell... thats just horrible

262627

[nathanwhite]

Then stuck on the gear lever..had a horrible moment when I thought the gear box wasn't going. It went from N to 1st but wasn't moving up to 2nd. Then I remembered its a sequential gearbox and needs some form of movement to switch gears :duh:

262630

Rear brake lever went on too. Had a hell of a time getting the rear part of the lever attached to the drum. That was after I worked out the order they were supposed to go and then fit together too. There is a spring around somewhere (I haven't lost it, I swear) that connects onto the lever to pull it back up. It hasn't gone on.

262631

Then I got out my nice oily shiny new chain, broke it at the required amount of links and stuck that on. Unfortunately I don't have a proper chain breaker, so I had to make do with a grinder, a hammer and a hole punch. :shit: It was a horrifying experience that I do not want to repeat, so I jumped on trademe and ordered one up quicksmart for the next time I have to do that.
262632

It's funny with this build, I'm half building the bike, and half playing hide and seek with all the parts scattered around the garage. It wasn't till after I installed the chain that I found the circlip that holds the gear lever in place

[Fast Eddie]

great build man it looks mint!

[superman]

There should be far more threads like this! Absolutely awesome.

[Mom]

Seriously. :headbang:

Is that carpet I could see in some of those pics Doogle? What about that grass??!!!!!!!


:spanking: :laugh:


I can not believe that I have only just found this thread. What an amazing job you have done.

PS: I hope that vernier serves you well young man, it seems to have found a very worthy home :love:

[nathanwhite]

great build man it looks mint!

There should be far more threads like this! Absolutely awesome.

Thank you's both. Very nice to hear these things


Is that carpet I could see in some of those pics Doogle? What about that grass??!!!!!!!



Carpet? no. The bike sits on lino and the caliper was on the workbench. There is carpet on the other half of the garage but I dont go there:no:. Dad is already a little irritated at how much mess I'm making and has made sure I'm not spreading it around. :laugh:

[ducatilover]

Good work man, exhaust looks a million times better!

Why do people call us both Doogle, this is odd looking at my nick name in posts :facepalm:

[Mom]

Dad is already a little irritated at how much mess I'm making ...

Bloody parents eh?

:laugh:

[nathanwhite]

Why do people call us both Doogle, this is odd looking at my nick name in posts :facepalm:

Funny innit? Only the KB crowd calls me Doogle.

[nathanwhite]

I'm starting to think about wrapping the exhaust. The midpipe looks fine, but the header still is pretty horrible and I don't think there is any way I can get back to a full shine. I do like the look of wrapped exhausts, but I've never seen them on their own. The bike always has had some other fairly major modifications done to it. Still could be a good excuse eh?

I've found a roll on TM here (http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/exhaust/auction-468208961.htm) are there any places that also sell it?

[ducatilover]

I personally don't like the look, thought about high temp coatings? Will work better in theory and the wrap may trap moisture and rust your headers to buggery.

[nathanwhite]

with the moisture/rust thing, i've heard a lot of 'yes it does' and 'no it doesn't.' I think if you get it wet when the bike's not running then yea, but if it's either running or sitting dry in a garage its not going to get wet. Even if it does, wouldn't it all evaporate when you get going?

[ducatilover]

Fair points, I've heard people claim it has rusted their pipes.
Might be worth a shot anyway, it looks dirty as... hmmm I should wrap the GN pipes, if it rusts, too bad, it's gay.

[nzspokes]

with the moisture/rust thing, i've heard a lot of 'yes it does' and 'no it doesn't.' I think if you get it wet when the bike's not running then yea, but if it's either running or sitting dry in a garage its not going to get wet. Even if it does, wouldn't it all evaporate when you get going?

It just drys when it runs. Mine was fine on the Honda. Segdins auto parts has it. Cheap as chips, I think mine was $17 with 6 clamps(which you need) and enough for 2 pipes. It may change your jetting.

[Fast Eddie]

lol on the mess/occupation of garage topic, when i was 16 my first car was an ooolld mercedes which I soon set about strippin to rebuild.. first the garage was all mine... and then the parts started migrating into the house.

oooo weee hahaha

[Armi]

Now this little bit came out the bottom (I think) and I have no idea where exactly it's from. Does anyone know what it is? or even could be?

HAHAHA! That's exactly what happened when I cleaned my FXR carb!! :killingme

http://www.kiwibiker.co.nz/forums/showthread.php/140198-Help-to-identify-part-(FXR150)

[nathanwhite]

Righty! now that our internet has rolled over I can start uploading photos and stuff with my usual abandon :msn-wink:

Havent done an awful lot actually though, got the rear tray/mudflap on

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG029-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG029-1.jpg" border="0" alt="Photobucket"></a>

and the taillight bracket cleaned up and stuck on

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG030-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG030-1.jpg" border="0" alt="Photobucket"></a>


I also bought myself a chain breaker from TM, nice and cheap. It's not brilliant and I would harldly describe the chain in 'good condition' after wards....

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG031-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG031-1.jpg" border="0" alt="Photobucket"></a>

but it does no damage to the other section of chain which is good, as long as I don't break off too many links.


In other news I got myself some race leathers (I'll post up a pic soon I promise) however when I got them home I found a hole that the slider was covering :mad: they were adverised in 'as new' condition which I'm kinda miffed about.... ah well, that'll learn me to fully check stuff before I buy

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG032-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG032-1.jpg" border="0" alt="Photobucket"></a>


I tried flipping the bars upside down and found that they dont really fit properly, and can't turn all the way to the stops also. So I'm just going to have to run them the right way up for now

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG035-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG035-1.jpg" border="0" alt="Photobucket"></a>

Also took the gauges off the bracket, things wern't working anyway so so no biggie.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG037-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG037-1.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG038-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG038-1.jpg" border="0" alt="Photobucket"></a>

and yes the key is in the ignition damn the consequences! I'll most likely end up rewiring it for a killswitch on/off anyway.




and for a bit of a gripe, for the last day or two I've been greeted with this in the garage . . .

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG036-1.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG036-1.jpg" border="0" alt="Photobucket"></a>

looks like i'm going to have to pull the forks apart again:mad::mad::mad::brick::brick::brick:
just for a ballpark, any idea what would cause a slow leak of fork oil?

[ducatilover]

I have a basic ignition barrel/key set up at my parents place, if I can find it next time I'm down there you can have it.
Put some clubman bars on it :D

Can you link me to the chain breaker? I want one, easier than using the angle grinder...

Excellent progress dude :niceone:

[nathanwhite]

Put some clubman bars on it :D


ooh, thats a cool idea



Can you link me to the chain breaker? I want one, easier than using the angle grinder...


This (http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/chains-sprockets/auction-474335326.htm) was the same one I got, but I think mine was just outta the packet or something. It was a little cheaper then this.

However some looking reveals some more good deals
http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/chains-sprockets/auction-474084449.htm
http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/chains-sprockets/auction-473634090.htm

or this is you really like comprehensive tool sets (http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/other/auction-474667544.htm)

[ducatilover]

ooh, thats a cool idea



This (http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/chains-sprockets/auction-474335326.htm) was the same one I got, but I think mine was just outta the packet or something. It was a little cheaper then this.

However some looking reveals some more good deals
http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/chains-sprockets/auction-474084449.htm
http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/chains-sprockets/auction-473634090.htm

or this is you really like comprehensive tool sets (http://www.trademe.co.nz/motors/motorbikes/parts-for-sale/other/auction-474667544.htm)

Clubman bars rule!

Some decent deals there, my dad made a chain breaker for push bikes years ago, might see if he can whip up a beefier one.
That full on kit is very cool :niceone:

[nathanwhite]

No pictures in this update sorry barely touched the bike in the last coupla days, 'cept to semi polish the rims somewhat.

The important thing is that I went to a bucket practice meet today and had a look at some of the FXR150's there. They have the same caliper as my EN, just for the other side of the wheel. So if I can find one on the cheap, I'll just have to flip the wheel and swap the forks around and I'll have a working bike!


Buckets were seriously fun too. Had a blast today

[Henk]

If the ignition switch only has two wires coming out of it consider replacing it with a telemechanique switch. Not sure where you'd get one or what they are worth as I got mine out of the trash at work but if you want to check one out come and see me at buckets sometime.

[nathanwhite]

OK! got stuff done today, though not all I wanted, but more on that later,

Cleaned up these side panel frame cover thingys (they go between the footpeg and the pillion footpeg)

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7535.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7535.jpg" border="0" alt="Photobucket"></a>

At the same time I was thinking of rearsetting the footpegs and after a minute scratching my head I worked out that where I wanted them to be was right where the pillion footpegs are already. Which is sweet, I just have to work out a way of getting the shifter back there also.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7537.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7537.jpg" border="0" alt="Photobucket"></a>

I also got my hands on a FXR150 caliper the other day :banana: The only major system I need to get running now is the front brake.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7539.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7539.jpg" border="0" alt="Photobucket"></a>

So I started pulling the caliper apart to clean it out, started with the bleed thing (note my terminology)...Lotsa rust there going to have to give it a decent clean.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7540.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7540.jpg" border="0" alt="Photobucket"></a>


Then I popped down and picked up a nice little blowtorch to try and force the bolts out with heat
They didn't have any of the pistol grip/stick it on a bench type though :(

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7541.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7541.jpg" border="0" alt="Photobucket"></a>


Funnily enough however only one bolt stuck, and that one was not coming out for heat, WD40 or anything else I threw at it.

In the end I ended up putting the frame bracket in the vice and hitting the caliper bracket with a hammer. Did the trick

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7542.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7542.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7543.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7543.jpg" border="0" alt="Photobucket"></a>

and then pulled one of the bolts in the caliper that holds the pads.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7544.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7544.jpg" border="0" alt="Photobucket"></a>

The other one however would not give. For heat, for cold, for wd40, or for massive amounts of torque. :mad::mad: The bolts are quite unusual in design so I can't strip the head (too much, I have some already and had to use a allen key .5mm bigger.) ANY help on how to get that out would be very much appreciated.


While that was happening I got into cleaning the pillion footpegs (surprising how many bits in one footpeg)

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7545.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7545.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=IMG_7546.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/IMG_7546.jpg" border="0" alt="Photobucket"></a>

I didn't manage to get a picture of them assembled (too irritated about the brake pad bolt) but the are all nice and shiny (not quite DL shiny though)



The bolt in the caliper is still not out, I've left it covered in wd40 in hopes that some of it will wick down the thread overnight and help it get out.

[nathanwhite]

Bit more pottering done, I'm down to a shoestring budget for ... ... well everything really, Rego for the scorpio is due in a couple of weeks, so I'm still scratching my head as to how i'm going to pay that. (here's hoping for extra shifts tomorrow) let alone the tools and materials i'm finding myself needing.

anyway, thats not what's important, just an explanation of why things are going slowly. Onto the bike!



Started off with the bar ends, all lovely bent and scratched from where the bike was dropped (and possibly slid)

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols001.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols001.jpg" border="0" alt="Photobucket"></a>

So pulled it all apart, cleaned it, blued where the bolts were bent (because what other reason would you have a gas torch for? :D) and straightened

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols002.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols002.jpg" border="0" alt="Photobucket"></a>

and back together all nice shiny and straight

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols003.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols003.jpg" border="0" alt="Photobucket"></a>

Now eventually i'm going to replace the heavy metal ends with some nice slider material, to help save the bike when I come off (because its going to happen eventually) but for the meantime, they are not too bad


Then I turned my attention to the shifter. As i'm rearsetting the footpegs by quite a bit, I'm going to have to do drastic things to get the controls going also.
In this case I think a longer bolt will be the easy and simple answer.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols004.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols004.jpg" border="0" alt="Photobucket"></a>

Funny story here, it ended up being not so simple and easy, after several hours of scratching my head, measuring, comparing threads etc I finally worked out that the reason the long bolt was only working on one of the connector things. The other one has a left hand thread :facepalm::lol:

So then I started thinking about how I would get them connected now I knew how they went, and tried a couple of things (that didn't work)

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols005.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols005.jpg" border="0" alt="Photobucket"></a>

and about this time, Dad stuck his head around the corner, pointed out how silly this was, and said he'll snaffle a 20mm long steel rod and a 6mm tap from work. Easy.



So then it was time for the rear brake. Now the car pedal type thing that it is won't move as easily as the shifter so something else is going to be needed.
I had a look in the small shed and saw my old push bike I used to do a paper run on. Hmmm.....

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols006.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols006.jpg" border="0" alt="Photobucket"></a>

Grabbed it and started stripping off the controls. Who said the rear brake HAD to be controlled by your foot?

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols007.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols007.jpg" border="0" alt="Photobucket"></a>

15min after that (when I worked out that the cable was not nearly long enough) I grabbed the control cable from the rear gear selector, (cleaning them as I went of course) and look at that! I have 3/4 of the solution for the rear brake sorted.

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols008.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols008.jpg" border="0" alt="Photobucket"></a>

There is plenty of cable left over for fine tuning the length later on. :cool:
<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols009.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols009.jpg" border="0" alt="Photobucket"></a>

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols010.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols010.jpg" border="0" alt="Photobucket"></a>


I'm going to have to go to a push bike shop and get the ends of the cable crimped with an end that suits the lever and that little thingamabob that turns the rear brake drum.



And that was all I planned to do.




Then I looked sideways at the handlebar on the pushbike and thought, hmmm.....

<a href="http://s1066.photobucket.com/albums/u417/nathanwhite2/?action=view&amp;current=movingcontrols011.jpg" target="_blank"><img src="http://i1066.photobucket.com/albums/u417/nathanwhite2/movingcontrols011.jpg" border="0" alt="Photobucket"></a>

I think so.

Its a little fatter in the middle, but that's nothing that can't be worked around. The benefits are that I get a workable handlebar for free and its' the same size (on the ends anyway) as the stock bar

[ducatilover]

Wicked update man! Go the fat bars

[nathanwhite]

ok! so things are going quite slowly at the moment ("no duh!" I hear you say) and I do have a reason for that.

:Offtopic:
I present, my Dozer scene which has altogether too much of my blood sweat and tears poured into it.

<iframe src="http://player.vimeo.com/video/44215213" width="400" height="300" frameborder="0" webkitAllowFullScreen mozallowfullscreen allowFullScreen></iframe>

EDIT: I don't know if the embed worked, cant see it. If not heres the link
http://vimeo.com/44215213

Everything there except the excavator and car modelling I did. All the textures, Environment, Animation etc. However back to the main topic!





The fat bars had the obvious disadvantage of being fat in the middle which means they didn't fit my risers. So I tried the handlebars from another bike we had lying around.

No go. The centre section is too narrow for risers too fit properly too.

<a href="http://imgur.com/Tw3L5"><img src="http://i.imgur.com/Tw3L5.jpg" title="Hosted by imgur.com" alt="" /></a>

Hrm.



Leaving that for the time being, I moved onto getting the controls moved to go with the new footpeg locations.

The coupling thingy is just 10mm rod with a 6mm tapped hole drilled in the middle. Because the shifter side of the connecting rod has a left hand thread, I've used the original connecting rod and coupled it to the longer one.

<a href="http://imgur.com/zNt1l"><img src="http://i.imgur.com/zNt1l.jpg" title="Hosted by imgur.com" alt="" /></a>

The new shifting rod in it's entirety

<a href="http://imgur.com/ZNtPE"><img src="http://i.imgur.com/ZNtPE.jpg" title="Hosted by imgur.com" alt="" /></a>


Then to get the actual foot control in place I got a shim type thing made up. (because I don't have a metal lathe :( ) 15mm steel rod turned down to just under 12mm to fit inside the shifter. The flange at one side is to hold the shifter in place and the step down on the other side holds a washer.

<a href="http://imgur.com/1vR9V"><img src="http://i.imgur.com/1vR9V.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/BevLD"><img src="http://i.imgur.com/BevLD.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/fvgYd"><img src="http://i.imgur.com/fvgYd.jpg" title="Hosted by imgur.com" alt="" /></a>

Here it all is mocked up on the bike, the shifter is hanging low, but it all looks like it's going to work.

<a href="http://imgur.com/dFbLd"><img src="http://i.imgur.com/dFbLd.jpg" title="Hosted by imgur.com" alt="" /></a>




Annnnnnnd it doesn't.

<a href="http://imgur.com/ejztU"><img src="http://i.imgur.com/ejztU.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/3T3ws"><img src="http://i.imgur.com/3T3ws.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/UocHX"><img src="http://i.imgur.com/UocHX.jpg" title="Hosted by imgur.com" alt="" /></a>

It's not nearly as obvious in the pictures, but not only is the rod bent, the coupler is hard up against the frame :cry:
The only workaround I see is getting a new shifter with the connector on the other side. which I imagine is not going to be the easiest.

[nzspokes]

Space the shifter out.

Bike shop wont crimp the ends. Unless you can find one that hasnt moved on from the 70s. Bicycle brake cable will not handle the loads, gear cable even less so.

Bicycle handlebars are 25.4mm and motorcycle are 22.2mm(unless over sized).

[nathanwhite]

Ok, coupla things done. First and most importantly, the shifter is done. :woohoo:

Took another crack at the brake caliper, acting on one of the most non destructive suggestions I had, I dripped some battery acid on top of the bolt and leave it to work it's way down whatever gap there is hopefully getting rid of the corrosion.

<a href="http://imgur.com/0N6E1"><img src="http://i.imgur.com/0N6E1.jpg" title="Hosted by imgur.com" alt="" /></a>

didn't work.

Onto the next one, heating the entire caliper in the oven and then spraying freeze on the bolt. Also didn't work, and now the kitchen smells like various burned lubricants and solvents. oops.

Turning my attention to the shifter, my dad (awesome guy) managed to flog 6mm bolts of varying lengths and a spacer for me to try on the shifter

<a href="http://imgur.com/iJo37"><img src="http://i.imgur.com/iJo37.jpg" title="Hosted by imgur.com" alt="" /></a>

The spacer worked brilliantly

<a href="http://imgur.com/ZLcJw"><img src="http://i.imgur.com/ZLcJw.jpg" title="Hosted by imgur.com" alt="" /></a>

except it was a little too small and didn't hold the shifter in place horizontally

<a href="http://imgur.com/Qwg4L"><img src="http://i.imgur.com/Qwg4L.jpg" title="Hosted by imgur.com" alt="" /></a>

So I drilled a bigger hole in a whole bunch of washers and slid them over the spacer to keep the shifter in the place.

However now, due to the positioning of the shifter, when I moved the shifter it started bending on the pivot now :angry2:

<a href="http://imgur.com/2usP3"><img src="http://i.imgur.com/2usP3.jpg" title="Hosted by imgur.com" alt="" /></a>

After a bit of pondering I flipped the other end of the shifter, chopped ~15mm off the connecting rod to make it all fit and Voila!

<a href="http://imgur.com/EdMTM"><img src="http://i.imgur.com/EdMTM.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/drqg8"><img src="http://i.imgur.com/drqg8.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/1NAby"><img src="http://i.imgur.com/1NAby.jpg" title="Hosted by imgur.com" alt="" /></a>

Hooray!!



Then as a time filler, I made up spacers to compensate for the gap left behind from the plate things under the footpeg and shifter.

<a href="http://imgur.com/2xSgf"><img src="http://i.imgur.com/2xSgf.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/Urwk6"><img src="http://i.imgur.com/Urwk6.jpg" title="Hosted by imgur.com" alt="" /></a>



I started looking at this space wondering if I could do anything about the gaping chunk on the engine.

<a href="http://imgur.com/hkY3L"><img src="http://i.imgur.com/hkY3L.jpg" title="Hosted by imgur.com" alt="" /></a>

Turns out I could. I got the cover and cut very carefully (not) into it where the shifter rod was sticking out.

<a href="http://imgur.com/LxEM9"><img src="http://i.imgur.com/LxEM9.jpg" title="Hosted by imgur.com" alt="" /></a>

and look at that.

<a href="http://imgur.com/KC1Uy"><img src="http://i.imgur.com/KC1Uy.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/ECK2h"><img src="http://i.imgur.com/ECK2h.jpg" title="Hosted by imgur.com" alt="" /></a>

maybe I took out a little more then I should have, but it looks a damn sight better then it did.

[nathanwhite]

Coupla things for the future,

Despite the fat bars thought I had, I've found some clip ons on TM which look pretty good. So I'm probably going to go for those instead of any bars.

Also with the cable controlled rear brake, I'll get a shop to make up one the right length when I get the clip ons. With a shop made one, I can have the two end made to fit then connectors I have.

[ducatilover]

You want a 4 piston caliper instead of that little toy? :innocent: Just make an adapter bracket and BOOM, big brakes.
If you want one, PM me, I'll strip one down/clean it and send it up. Might even have some okay pads too.

[Mom]

Nice camera work young Doogle :yes:

[nathanwhite]

Nice camera work young Doogle :yes:

You should have seen me taking that photo of the bike side shifter rod. Lying down I was, almost under the bike. :lol:

[Tigadee]

Nice camera work young Doogle

+1 10 char

[nathanwhite]

Nice camera work young Doogle :yes:


+1 10 char

Thank you both. My best pics always seem to be the one's I don't put much thought into for some reason. :scratch:

[nathanwhite]

A new part arrived in the mail yesterday :D

<a href="http://imgur.com/Nrh4s"><img src="http://i.imgur.com/Nrh4s.jpg" title="Hosted by imgur.com" alt="" /></a>

So out in the garage to get it installed or at least the bike prepped for installation
However once I got the airbox out I realized that it's still quite a busy area with battery/cables and other bits and bobs there

<a href="http://imgur.com/0dCt0"><img src="http://i.imgur.com/0dCt0.jpg" title="Hosted by imgur.com" alt="" /></a>
<a href="http://imgur.com/TnnfM"><img src="http://i.imgur.com/TnnfM.jpg" title="Hosted by imgur.com" alt="" /></a>
<a href="http://imgur.com/duJsp"><img src="http://i.imgur.com/duJsp.jpg" title="Hosted by imgur.com" alt="" /></a>

and it was about this time I started to seriously think I would have to relocate the battery. What. A. Pity.
:eek:
I'm actually quite liking this idea because it's something I've never done before and I repurposing/rebuilding/making stuff from scratch. It's a surprisingly rewarding feeling taking scrap metal or stock and making something useful/efficient/pretty from it. (makes me want a milling machine also)

So out the rear mudguard / undertray thing came (again)

<a href="http://imgur.com/TRRUp"><img src="http://i.imgur.com/TRRUp.jpg" title="Hosted by imgur.com" alt="" /></a>

and when having a look around I saw these two mount points that I thought would be prefect for attaching the new battery holder to.

<a href="http://imgur.com/UG5D5"><img src="http://i.imgur.com/UG5D5.jpg" title="Hosted by imgur.com" alt="" /></a>

So it would sit something like so

<a href="http://imgur.com/dmY51"><img src="http://i.imgur.com/dmY51.jpg" title="Hosted by imgur.com" alt="" /></a>

So down I went to mitre 10 to get some Aluminium stock and I'll report back when I've made it up.

A little before the trip to the hardware store however I had some time on my hands and I thought "wouldn't it be cool if I had a dash of some form?" I've always liked the idea of a gear indicator and was a little unhappy that was going, so I decided that it wouldn't. To get rid of it completely also would entail cutting a cable out of the engine and that was something I wasn't totally willing to commit to just yet. So I started cannibalising the dash.

<a href="http://imgur.com/l6Pgt"><img src="http://i.imgur.com/l6Pgt.jpg" title="Hosted by imgur.com" alt="" /></a>

Five of these lights are the gear indicators and one is the neutral indicator. The rest are various idiot lights and dash-lighter-uppers.

<a href="http://imgur.com/m8veL"><img src="http://i.imgur.com/m8veL.jpg" title="Hosted by imgur.com" alt="" /></a>

Unfortunately to get the two sets of lights apart I had to destroy the plug on the other cable. (and Yes I mean destroy)

<a href="http://imgur.com/yeYwv"><img src="http://i.imgur.com/yeYwv.jpg" title="Hosted by imgur.com" alt="" /></a>

This was necessary because the negatives of ALL the lights (with individual cables no less) went into this other cable.

So it's all out now and when I find/buy something to use as a dash I'll get that all working.


In the next day or two I'll have the battery holder done and mounted, wires and components tidied and the pod filter installed. I haven't done it yet because I want to finish poking pulling and twisting things in that area first so I don't damage it. hehe, it's shiny.

[ducatilover]

I'm doing the same thing with the battery to my GN so it looks cool without covers on :niceone: I love custom dash units! I made the one for the 600, hours of plastic welding, filling and sanding and it's fucking awesomesauce.
I'm liking this build!
Hopefully will get time to do that brake caliper for you and inspect the master cylinder too :msn-wink:

[ducatilover]

Have a look at C2345.com, you can get all sorts of bit there, chain guards, piston kits...anything you want, cheap. I've found a set of clip ons I may buy for the GN and am going to get a set of fork gaitors too.

[nathanwhite]

Have a look at C2345.com, you can get all sorts of bit there, chain guards, piston kits...anything you want, cheap. I've found a set of clip ons I may buy for the GN and am going to get a set of fork gaitors too.

Chinese eBay, nice. I'll have a more indepth look a bit later on.


Now for what I did today,

I was looking at the frame and holding my battery working out exactly how I was going to connect things all together nicely when it occurred to me that I may not want to have my battery hanging on with only two m6 bolts. Now I suspect that if I got some really hard bolts it wouldn't be an issue, but seeing as I don't have those and I do have some nice flat aluminium stock I thought I may as well use that to hang it off the frame.

I had to use rivets, because I don't have a TIG welder and even if I did manage to get my dirty mitts on one, I wouldn't be able to use it much at all.
Five hours of marking, cutting, hammering, drilling, filing, riveting, head scratching, re measuring, bending the stock juuust so,
I had this:


<a href="http://imgur.com/DEtqs"><img src="http://i.imgur.com/DEtqs.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/RfPh0"><img src="http://i.imgur.com/RfPh0.jpg" title="Hosted by imgur.com" alt="" /></a>

BEHOLD the first bike part completely fabricated by me!
The likes of which you will never see from ducatiLover or Bogan.
It's out of line!
It's not square!
It's a little too small!
It doesn't even fit the battery properly!!

:killingme

<a href="http://imgur.com/pCSwT"><img src="http://i.imgur.com/pCSwT.jpg" title="Hosted by imgur.com" alt="" /></a>


But for now however it will do. It was getting late when I finished it and so I decided to leave it for now.

Fitted to the bike
<a href="http://imgur.com/Gw7Hi"><img src="http://i.imgur.com/Gw7Hi.jpg" title="Hosted by imgur.com" alt="" /></a>


Now if you listen to ducati lover long enough two two things become apparent. One is that autosol is the greatest thing on the planet, and that visible cables on a bike is a sin and God kills a kitten every time you leave a visible one on your build.

I share his sentiment for tidiness, but not quite to the same degree. So a coupla minutes of black tape does me just fine.

<a href="http://imgur.com/Kdt5K"><img src="http://i.imgur.com/Kdt5K.jpg" title="Hosted by imgur.com" alt="" /></a>

About half of the wires back here are useless now, going to blinker relays and whatnot so tomorrow I'm going to rip those out.

<a href="http://imgur.com/5QpSl"><img src="http://i.imgur.com/5QpSl.jpg" title="Hosted by imgur.com" alt="" /></a>

I do like this black ribbed tube thing though. I think that's a design element I'll try introduce into future builds......

<a href="http://imgur.com/EBKXb"><img src="http://i.imgur.com/EBKXb.jpg" title="Hosted by imgur.com" alt="" /></a>



And then for the giggles I installed the pod filter

<a href="http://imgur.com/gMAuu"><img src="http://i.imgur.com/gMAuu.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/Zvk2q"><img src="http://i.imgur.com/Zvk2q.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/fX98n"><img src="http://i.imgur.com/fX98n.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/EQQBc"><img src="http://i.imgur.com/EQQBc.jpg" title="Hosted by imgur.com" alt="" /></a>

:eek:

[Mom]

I'm liking this build!

Encourage this youngster, he is worth the energy :yes:

Also tease him, for it is good for him :innocent:


I do like this black ribbed tube thing

Ribbed for pleasure Doogle, remember that :devil2:

[ducatilover]

Wait... people have listened to my ramblings? You fools!!!

I like the battery tray, that is proper class and being square ain't always fun, just ask any slut, they're never square and they have heaps of fun and many look good.
Which now means your batter tray is a slut. :bleh:

[nathanwhite]

Ribbed for pleasure Doogle, remember that :devil2:

Oh you know it Guuurl. :msn-wink:



Which now means your batter tray is a slut. :bleh:

Maybe I should stretch it out a little, make it more 'one size fits all'?

[ducatilover]

Maybe I should stretch it out a little, make it more 'one size fits all'?
I had a missus like that! :lol:

I love what you've done by rear-setting it. I'd like to move mine back 50mm or so (so the peg is inline with the lower bracket bolt)

[nathanwhite]

I love what you've done by rear-setting it. I'd like to move mine back 50mm or so (so the peg is inline with the lower bracket bolt)

It was a lot easier for me because I just took out the main footpegs and put in the pillion ones. I do worry that when it comes time to ride the sucker these footpegs will end up too far back and up and Ill have to go with more conventional rearsets. It would be nice to make it out of an aluminium billet, but with no milling machine, I would have to get creative with a hacksaw and several files :lol:

You wouldn't happen to know how to make one fairly cheaply at home by any chance?

[ducatilover]

I have ideas, but CNC made will be the way to go, I know a chap who could for the right $$. I'm thinking about it for mine, but trying not to do anything that costs money as it's meant to be a super budget build lol

[nathanwhite]

Spend an hour in the shed today ripping out the now useless wires.

<a href="http://imgur.com/9OkzI"><img src="http://i.imgur.com/9OkzI.jpg" title="Hosted by imgur.com" alt="" /></a>

Not an awful lot, but it helped tidy up the loom and frame somewhat

<a href="http://imgur.com/EfvSh"><img src="http://i.imgur.com/EfvSh.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/K5kvh"><img src="http://i.imgur.com/K5kvh.jpg" title="Hosted by imgur.com" alt="" /></a>

[nathanwhite]

Debadged the tank last night, then for the giggles, put the tank and seat on. Left the doors to the shed open when I went inside to get something and came back out to see this :cool:


<a href="http://imgur.com/qJwV0"><img src="http://i.imgur.com/qJwV0.jpg" title="Hosted by imgur.com" alt="" /></a>

Yes I know the wall is a little bare, it's because the bike lives in the shed, and the garage holds all the tools.

[Mom]

Look what you have done Doogle! Boy that looks great, cant wait to see it in the flesh so to speak.

[RDjase]

Funny innit? Only the KB crowd calls me Doogle.

http://www.doogle.org/

Good search site :lol:

[nathanwhite]

Handlebars arrived!

hmmm, little bigger then I thought
<a href="http://imgur.com/aiDzR"><img src="http://i.imgur.com/aiDzR.jpg" title="Hosted by imgur.com" alt="" /></a>

I pulled the cross bracing off, threadlocker didn't do much at all to hold it together
<a href="http://imgur.com/K21oO"><img src="http://i.imgur.com/K21oO.jpg" title="Hosted by imgur.com" alt="" /></a>

Mocked up on the bike

<a href="http://imgur.com/CL1YI"><img src="http://i.imgur.com/CL1YI.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/G9nVu"><img src="http://i.imgur.com/G9nVu.jpg" title="Hosted by imgur.com" alt="" /></a>

and controls (the working one's anyway)

<a href="http://imgur.com/hnMQ5"><img src="http://i.imgur.com/hnMQ5.jpg" title="Hosted by imgur.com" alt="" /></a>

<a href="http://imgur.com/cx9kz"><img src="http://i.imgur.com/cx9kz.jpg" title="Hosted by imgur.com" alt="" /></a>


It does seem quite wide, almost disproportionally so. However when sitting on the bike and shifting from where these controls are to where clipons/clubmans would be, I do like this position better.
A slight issue I noticed, I cannot reach the gear lever without moving my foot completely off the footpeg, my foot doesn't bend that far sadly. It shouldn't be too much of an problem, but I'll have to wait until I can actually ride it.

[Henk]

Haven't read the whole thread but from another gather that this is a bucket build. Nice work so far.
I'd consider trimming the bars down so they aren't as wide. I've seen wide bars cause crashes for others when a rider coming around the outside has hooked the bars with their elbow, standard width dirt bike bars in that instance and happend to the same rider a couple of times. things can get quite tight on track at times.
For the rear sets ali plate and hacksaw / file work is fine I've done about five sets like that and it takes a bit of time but works fine, 10 or 15 mm plate seems the biz from a crash ability point of view.

[nathanwhite]

Thanks! Only reason this isn't in buckets is because it didn't start out with this intention

This is the first time i've really messed around with a bike, so I'm still trying to find what works and what doesn't. That's a good idea re the ali plates, however because the build is being driven by a shoestring budget i'm exploring the cheapest options before the most practical ones. Once it's up and running (just need to sort out the brakes really) I'll be looking at stuff like that.

[nathanwhite]

I'd consider trimming the bars down so they aren't as wide. I've seen wide bars cause crashes for others when a rider coming around the outside has hooked the bars with their elbow, standard width dirt bike bars in that instance and happend to the same rider a couple of times.

I had a quick look and shuffle around of the controls today, I can trim ~45mm off each side before there isn't enough room for the controls. Definately going to do that now, just have to wait to get all the bits bought, assembled and ready to go so I know exactly how much to chop

[ducatilover]

You've done exactly what I am doing when my new bars arrive...that also look exactly the same as yours. Oh dear me lol

[nathanwhite]

Before I go blow up form irritation, how exactly does one measure a wheel diameter?

[ducatilover]

Double the radius of course mate?

[nathanwhite]

So I've had a two week holiday, didn't go anywhere just bumbled around the garage, made myself a lightsaber without having to think about anything bike related, but that's another story.

Other Doug's awesome caliper turned up and many smiles were had.

Then they stopped rather abruptly when I tried to see how it would fit.

Seeing as it's a 4 pot caliper rather then a 2 pot one, it sticks inward from the disc quite a bit more then the factory one. Now this wouldn't be a problem on a big 600 front wheel, but I don't have that that kinda space to maneuver in. Infact I'm short about 10mm.
The caliper is hitting into the spokes of the wheel meaning mounting the caliper is not going to be as simple as an adapter plate. After a bit of thought I supposed I could space out the disc to the required amount, but then after some more thought I realized that this could seriously play havoc with the handling...

I'm a little out of my depth here (as usual) so any insight regarding the matter would be helpful

[ducatilover]

How much rotor to fork clearance have you got?
I think you may just need bigger hammer :D

[nathanwhite]

I figured I needed some inspiration for this, so I went to start up the bike and have a quick blast around the lawn. Except of course the jolly thing wouldn't start. :angry2: so the weekend was spent trouble shooting. Finally got it down to a broken negative wire on the loom side of the magneto. Replaced and presto! Working bike.

So the blat up and down the front lawn showed me a couple of things I need to fix:


The bars a reallly wide. When I have the levers all setup, I'll trim as much of the bars off as possible.
The footpegs are really really far back and up. Almost like it wasn't designed for the rider to be using them, funny I know. It doesn't seem to be too much of an issue at this stage though(I'll need to get it on the (road)track to confirm) The big issue is that because the footpegs are so far back, the shifter is incredibly out of place.

[nathanwhite]

Sometimes the hardest problems

<a href="http://imgur.com/8u20y"><img src="http://i.imgur.com/8u20y.jpg" title="Hosted by imgur.com" alt="" /></a>

Have the easiest solutions

<a href="http://imgur.com/UfGJ1"><img src="http://i.imgur.com/UfGJ1.jpg" title="Hosted by imgur.com" alt="" /></a>
<a href="http://imgur.com/Wlpxb"><img src="http://i.imgur.com/Wlpxb.jpg" title="Hosted by imgur.com" alt="" /></a>
<a href="http://imgur.com/YMKib"><img src="http://i.imgur.com/YMKib.jpg" title="Hosted by imgur.com" alt="" /></a>



Typical. :rolleyes:







So after I had mocked it all up I pulled it apart again for a repaint because it parts of it looked horrible

<a href="http://imgur.com/bSlah"><img src="http://i.imgur.com/bSlah.jpg" title="Hosted by imgur.com" alt="" /></a>

Also going to have to get kinky with a knife and a file because the clutch lever is integrated with the left hand control box but the brake has it's own extra thingy beside the control box. In any case the effect is thus

<a href="http://imgur.com/NPt75"><img src="http://i.imgur.com/NPt75.jpg" title="Hosted by imgur.com" alt="" /></a>
<a href="http://imgur.com/OXm8L"><img src="http://i.imgur.com/OXm8L.jpg" title="Hosted by imgur.com" alt="" /></a>


and when you talk about different size master cylinders what is this referring to? I assumed the connection between the MC and the hose but when I measured the EN OEM one and DucatiLovers ZZR'sthey were the same (the EN's one was about .5mm bigger actually)

<a href="http://imgur.com/yBVFW"><img src="http://i.imgur.com/yBVFW.jpg" title="Hosted by imgur.com" alt="" /></a>

[koba]

Master cylinder size refers to the bore of the cylinder, not the coupling.

Read up about hydraulic ratios, here is a start: http://en.wikipedia.org/wiki/Hydraulic_machinery

EDIT: to be more specific:http://en.wikipedia.org/wiki/File:Hydraulic_Force_Torque_275px.png

Also, keep the 'bars wide; leverage is good on "wibbly wobbly" bikes.
(You have a very wibbly wobbly bike)

EDIT2: Now those massive pics have loaded I'll change that advice to say: don't chop the bars too short. Try them long and go from there.

[ducatilover]

I like the wibbly wobbly comment
I can make my GN have a wibble wobble by shaking my torso :facepalm:

It's awesome

[koba]

I like the wibbly wobbly comment
I can make my GN have a wibble wobble by shaking my torso :facepalm:

It's awesome

Dave Croxford coined the phrase. Cool guy.

[nathanwhite]

Not a lot done, but it's pretty awesome. This was all done a couple of weeks ago, I just haven't seemed to get around to uploading the pics.

So I wanted to build a dash unit for the bike, something simple that would house my on/off switch and the gear indicator lights (because I hadn't pulled the bike side connectors off just yet) After a bit of scrounging around for bits I found the origional headlight brackets. Hrm.

A little bit of bolting drilling and filing later

<a href="http://imgur.com/IhnaI"><img src="http://i.imgur.com/IhnaI.jpg" alt="" title="Hosted by imgur.com" /></a>
<a href="http://imgur.com/pFuuo"><img src="http://i.imgur.com/pFuuo.jpg" alt="" title="Hosted by imgur.com" /></a>

Looks good, onto fitting the bits!

Hole #1
<a href="http://imgur.com/77uYA"><img src="http://i.imgur.com/77uYA.jpg" title="Hosted by imgur.com" alt="" /></a>

holes 2-7 and filling in extra one
<a href="http://imgur.com/LKG3S"><img src="http://i.imgur.com/LKG3S.jpg" alt="" title="Hosted by imgur.com" /></a>

and a shroud for aesthetics sake
<a href="http://imgur.com/anv2T"><img src="http://i.imgur.com/anv2T.jpg" alt="" title="Hosted by imgur.com" /></a>
<a href="http://imgur.com/L3gzC"><img src="http://i.imgur.com/L3gzC.jpg" alt="" title="Hosted by imgur.com" /></a>
<a href="http://imgur.com/FA1xb"><img src="http://i.imgur.com/FA1xb.jpg" alt="" title="Hosted by imgur.com" /></a>

Painted it up and stuck a tube around the edges with (of all things) hot glue.
<a href="http://imgur.com/VWLn7"><img src="http://i.imgur.com/VWLn7.jpg" alt="" title="Hosted by imgur.com" /></a>

The trio of bolts under it is be the eventual fasteners for the race number


<a href="http://imgur.com/mc1RX"><img src="http://i.imgur.com/mc1RX.jpg" alt="" title="Hosted by imgur.com" /></a>

<a href="http://imgur.com/LKG3S"><img src="http://i.imgur.com/LKG3S.jpg" alt="" title="Hosted by imgur.com" /></a>


It's not perfect, but considering it didn't cost me anything I think it's pretty darn good. The filled hole didn't work out how I wanted it too and I may rip the paint off to redo that, but for now its fine

[nathanwhite]

THREAD DREDGE!!!


Cleaned out the shed today and got some schexy new rubber put on the wheels. Just have to get a brake line for it, and check that I havent fuxxored up this caliper too then some nice sliders and it should be track ready :D

[ducatilover]

:2thumbsup wheelies!

[nathanwhite]

Got it measured up for custom frame sliders. Who would have thought the GN frame would be a bitch for them eh?

[koba]

And then:

http://www.trademe.co.nz/motors/motorbikes/motorbikes/sports/auction-660474243.htm

[ducatilover]

:mad: Noooooooo

[nathanwhite]

290014

:cry:

I have no fancy words to say or anything I can find that is fitting.

With any luck, the new owner will get it running again and actually use it, unlike I did. He knows about this thread so there may even be a continuation of the work done in my stead.

Life moves and changes, I never imagined that I would spend the amount of time on this little bike that I did. It was a fantastic project, it taught me many things, and I do not regret what I have put into it at all. However it could not continue and I am glad that it's not going to be sitting forgotten in a shed anymore.

[ducatilover]

I have no fancy words to say or anything I can find that is fitting.



I'm fuckin' fitting.


Damn meth