Well, a quick update on slow progress.
I spent a few frustrating hours yesterday trying to rebuild the master cylinder. First problem was that the rebuild kit bore little resemblence to my own piston assy, and was in fact too big.
I assumed that my master cylinder was off a KLR 600 A1, but obviously not.
I now have a bit of a dilemma. I can't really send it back, as I opened it and actually fitted the outer dust seal.
I thought I might get away with the original seals, but after filling and bleeding, there was not much pressure being exerted, although I have no pads in yet, Once I have fitted thew new pads and front wheel, I'll try again. You never know your luck!
On the good side, got an E Mail today (Monday) saying that the tyre, tube and rim tape were on their way. Also, the new side stand arrived from Belfast, and quite a thing it is too!!
Well, here's hoping for an easy day at work tomorrow, and a couple of hours fitting stuff!
Monday 31 October 2011
Saturday 29 October 2011
Bits..bits...bits..!!
Well, today has seen a few bits arrive at last.
2 oil filters arrived, along with a master cylinder rebuild kit, and a bolt for the front brake lever, which was missing. It's not the correct one, but it'll do the job. 2 oil filters, as I am changing the oil after a few days, and then again after 200 miles, just to be safe. Also arrived, a spanking new NGK surpressed spark plug cap, which looks great, very retro, and some more electrical connectors, as I have used bloody loads!! Oh yes, and 5 metres of solder, always useful for....soldering stuff!
Not fitting anything today, too tired after a busy week at work, so off for a few beers tonight, and then set about sorting the master cylinder tomorrow morning. Have also bought a new rim tape, tube and rear tyre. over £100 but once that lot is fitted, and the replacement stand and front wheel, it will actually look like a proper bike, and aactually, will not be far from finished. Tyre is a Metzler Karoo, not used them before, but they get good reports around the world on KLR forums, so I'll give it a go. Will buy a new Metzler Karoo front when the bike is ready for the road, but the knackered old tyre on the front will do for moving around in the garden etc. Onward and upward !!
2 oil filters arrived, along with a master cylinder rebuild kit, and a bolt for the front brake lever, which was missing. It's not the correct one, but it'll do the job. 2 oil filters, as I am changing the oil after a few days, and then again after 200 miles, just to be safe. Also arrived, a spanking new NGK surpressed spark plug cap, which looks great, very retro, and some more electrical connectors, as I have used bloody loads!! Oh yes, and 5 metres of solder, always useful for....soldering stuff!
Not fitting anything today, too tired after a busy week at work, so off for a few beers tonight, and then set about sorting the master cylinder tomorrow morning. Have also bought a new rim tape, tube and rear tyre. over £100 but once that lot is fitted, and the replacement stand and front wheel, it will actually look like a proper bike, and aactually, will not be far from finished. Tyre is a Metzler Karoo, not used them before, but they get good reports around the world on KLR forums, so I'll give it a go. Will buy a new Metzler Karoo front when the bike is ready for the road, but the knackered old tyre on the front will do for moving around in the garden etc. Onward and upward !!
Sunday 23 October 2011
Quiet days
Well, today, Sunday, has been a pretty quiet day on the bike front. Not done much as I am now waiting (again) for parts.
I have got a new oil filter coming, a master cylinder re-build kit, and a brake lever pivot bolt + nut.
Stripped the master cylinder, and it was completely yuck inside! Have replaced the rubber brake line with a stainless braided one, which was on the original piece of scrap that I bought!! One of the few (Very few) parts that were worth keeping.
The caliper looks to be in excellent condition, and is not seized at all. I will build up the brake, and see how things look, then I will maybe replace the seal and piston, but it looks like they are all good.
Have cleaned up the rear wheel today, no rot, just some surface rust on the spokes, which cleaned up well with a wire brush on the drill.
I also stripped the side stand that I bought, as I need to get my good mate Harry to do some grinding on it to make it useable. The leg supplied is way too short, but it looks possible to replace it with the original leg. Heres hoping!
We'll see what comes in the post tomorrow, and I'll update after that!
I have got a new oil filter coming, a master cylinder re-build kit, and a brake lever pivot bolt + nut.
Stripped the master cylinder, and it was completely yuck inside! Have replaced the rubber brake line with a stainless braided one, which was on the original piece of scrap that I bought!! One of the few (Very few) parts that were worth keeping.
The caliper looks to be in excellent condition, and is not seized at all. I will build up the brake, and see how things look, then I will maybe replace the seal and piston, but it looks like they are all good.
Have cleaned up the rear wheel today, no rot, just some surface rust on the spokes, which cleaned up well with a wire brush on the drill.
I also stripped the side stand that I bought, as I need to get my good mate Harry to do some grinding on it to make it useable. The leg supplied is way too short, but it looks possible to replace it with the original leg. Heres hoping!
We'll see what comes in the post tomorrow, and I'll update after that!
Wednesday 19 October 2011
To spark or not to spark!!
 | |
| "Do you know what you're doing dad? Ha ha!!" |
As today was my day off, I decided to crack on with fitting and wiring everything and seeing what happened. This all had to wait until the afternoon, as the boss had some "Jobs" for me to do!!
Well, jobs done, I ventured outside to the bike, removed the covers, and set to work.
Firstly, I decided to un cover all the looms which I had previously covered, as I wanted to see for definite, which colour was which, and generally check everything was correct. I also had to expose the defunct 3rd generator wire, as I could now wire it into the reg/ rect unit. As the loom is for a 600, I had to make up a new wire for this 3rd output, but it all fitted fine.
Next I found which wires were the exciter coil wires, fitted them, and wired up the CDI. After about 1 hour, it was all done. I fitted the battery. I then felt a little nervous, would I now get a spark? Is the CDI ok ?
Turned the ignition to on, laid the plug on the head, kick...kick...kick..NO SPARK!! Bugger!!
Checked all connections again, all ok, so I decided to try a different coil, which I had bought a while ago, and found was the wrong one. After a bit of bodging about, fitting an earth to it for one, I switched the ignition to on again...Kick..SPARKS!!!!
Hurrah!! It works!!
So, I now know that all is well, apart from the coil. I will try and fit this new coil tomorrow somehow, it looks do-able, but if not, I'll get a replacement.
At least I can now crack on, didn't want to buy anything more until I knew the thing would at least try and run!!
Tune in tomorrow for updates!!
Saturday 15 October 2011
October Update
Well, it's been a while due to work and boring stuff like that, but here goes again.
After still no sparks, I have tested coil, which is new (2nd hand) and seems ok, Ignition switch, which is pretty basic and smacks of clutching at straws!! No joy, ie no faults, so unfortunately, it looks like the CDI units, which I have two of, supplied by the idiot. I assumed, though with no real reason, that at least one of them was ok, but have tried both and tested both as best I can, and It looks like they are faulty. Bugger.
So, forlornly, I scanned my good and trusted friend E-Bay once again for said units. After much searching and fruitless watching, I saw that they were going for lots of silly money, or were only available from Slovakia(WHY?)
So, after a break from it all spent researching my family tree, which was good fun, I resumed my E Bay searching, and found a bloke called Steve, in Swansea, who was selling bits from a KLR 650 Tengai.
I sent him a message asking if he had the rectifier / regulator and CDI unit, and if so, how much would it be, and lo and behold he got back to me and said yes, make me an offer. I offered £40, and amazingly, he said yes!! Eureka!!
I paid him immediately, and today, Saturday 15/10, he has posted them .I actually gave him £45 for it all, still a great bargain.
When they arrive, I'll wire it all up as a straight 650 machine, and hopefully I will get many many sparks!!
Then I will set about getting the wheels on, and sorting out a side stand. I have bought an after-market short bolton one, which I reckon I can adapt using the original KLR long stand leg. Time will tell!
Right, that's it for now, off to get ready now for a celebratory beer or 3, although Wales lost at rugby today, and Grimsby Town lost at York City, but I'm used to the latter, and the former was just bad luck!
After still no sparks, I have tested coil, which is new (2nd hand) and seems ok, Ignition switch, which is pretty basic and smacks of clutching at straws!! No joy, ie no faults, so unfortunately, it looks like the CDI units, which I have two of, supplied by the idiot. I assumed, though with no real reason, that at least one of them was ok, but have tried both and tested both as best I can, and It looks like they are faulty. Bugger.
So, forlornly, I scanned my good and trusted friend E-Bay once again for said units. After much searching and fruitless watching, I saw that they were going for lots of silly money, or were only available from Slovakia(WHY?)
So, after a break from it all spent researching my family tree, which was good fun, I resumed my E Bay searching, and found a bloke called Steve, in Swansea, who was selling bits from a KLR 650 Tengai.
I sent him a message asking if he had the rectifier / regulator and CDI unit, and if so, how much would it be, and lo and behold he got back to me and said yes, make me an offer. I offered £40, and amazingly, he said yes!! Eureka!!
I paid him immediately, and today, Saturday 15/10, he has posted them .I actually gave him £45 for it all, still a great bargain.
When they arrive, I'll wire it all up as a straight 650 machine, and hopefully I will get many many sparks!!
Then I will set about getting the wheels on, and sorting out a side stand. I have bought an after-market short bolton one, which I reckon I can adapt using the original KLR long stand leg. Time will tell!
Right, that's it for now, off to get ready now for a celebratory beer or 3, although Wales lost at rugby today, and Grimsby Town lost at York City, but I'm used to the latter, and the former was just bad luck!
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