More Bits !!!

Well, today, Tuesday 8th November, MORE bits arrived!!
The new original throttle grip came, and more importantly, the rear wheel spacer arrived. I would have liked to have fitted this today, but, as usual, stupid work got in the way! That and feeling like crap due to a cold bug which Donna, more worryingly, has also got. Ironically, it would seem we caught it at the vets!! Should have got a shot while we were there!
As the weather is also pretty crap this week, I think I'll get it all sorted at the weekend, when the new thermostat should be here as well. I will then be ready to fill up with oil, coolant, and maybe, if I dare, some fuel and give it a kick!!

Bonfire Night

Well, today is or will be, bonfire night, Nov 5th. A nightmare for Mac, one of our hounds, but the other Louie is not botheed with it all.
Anyway, back on the bike front, have now got both wheels on, although the back wheel is missing a spacer, which explains quite a lot, such as, wheel had rubbed away part of the upper chain guard, and the opposing side swing arm. I'm amazed the previous owner actually rode it and stayed alive!!
Anyeay, I've managed to get a replacement, new, spacer from good old E Bay for £6.99, a bargain, especially as they are not produced anymore!!
I'm hoping that it arrives on Monday, then  I can complete the back end. The front end is done, apart fron fitting the front mudguard, or for any Americans, the front fender! I have fitted the speedo cable, new front pads, although I still need to repair the master cylinder. It looks like I'll have to buy a replacement piston assy for it, but it's not expensive.
Have still got trouble sorting the side stand, and have not as yet decided exactly what to do. I've fitted the small replacement one that I bought, as the latest big one ended up to bloody big!! I'll get there though, it may be just need to get a pice welded on to extend the short one, which would be good, as it really is a strong piece of kit.
The chain, which looks almost new, has been bathed in a pool of gear oil, and is now hanging and draining in the workshop. Once the spacer arrives, I can fit the front sprocket, chain, front sprocket cover, and importantly, the neutral switch wire. There is still quite a bit to do, and it's a bit frustrating as money is always a factor, but it is making progress, although sometimes it's one step forward and two back.

New Arrivals!

Wahay!!
Today has seen the arrival of the new Metzler Karoo rear tyre, and a new inner tune with Rim tape.
I fitted the rim tape, and rushed it all round to Frost Tyres, where John soon had it all in one piece for the princely sum of £5.
Well worth it. Now looking forward to friday, when, after taking the dogs to the vets for their kennel cough vaccinations, I shall be getting a lot of stuff done.
Trial fitted the stand to a spare frame lower today too, and it fits perfectly. Hope thats the case actually ON the bike, but I'm sure it can be adapted if need be.

Anyway, friday hoping to fit both wheels, stand, chain, chain guard, front sprocket and guard.
In true Edd China fashion, I may need my mate Paul to help me on that bit as it's quite heavy, but it will probably end up being wife Donna instead!!
If it stays fine, maybe fit some bodywork, in fact it'll be nearly done!! Nah, a bit to do yet, but it's going the right way.

Slow progress

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!

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 !!

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!

To spark or not to spark!!

"Do you know what you're doing dad? Ha ha!!"

"

Right oh then, the replacement CDI has arrived, along with the replacement Regulator / rectifier.
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!!