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suspension was next...i forgot to take photos when i did the front end, i got rid of the stock springs and replaced them with progressive springs from Hyperpro and added 15 weight fork oil
on the rear end i took off the stock Sachs shock and got a Ohlins as replacement. I had emailed them months back to ask if they sponsored RTW riders, they said not 100% but would give me a substantial discount if i could prove that i was really doing it...that was easy i sent them a link to my blog!!! i got a $620 discount :rolltfl: if you don't ask you don't get, also they are doing my first service for free http://dmh65.smugmug.com/photos/i-2G...2GmXQKk-X2.jpg that Sachs shock has 50,001 miles on it, its the original unit, i think it held up pretty well considering what i have put it thru so it was time for the rear end to be stripped, cleaned and checked out http://dmh65.smugmug.com/photos/i-w5...w59TRqX-X2.jpg i found some damage below the left needle bearing area http://dmh65.smugmug.com/photos/i-BD...BDCqhrN-X2.jpg i found a new one on ebay UK today so ordered it, no choice!!! but for now everything is going back together and i will baby it until the new one arrives checked all the other bearings, no more problems. if you haven't done this its relativity simple to re-grease once its all apart, there are needle bearings and a pocket area for additional grease. If i was a designer at Yamaha i would add grease zerts to these bearing areas so the bike didn't need to be dismantled to grease them all the bearing were degreased, and then regreased using high temp bearing grease...and a little cleaning on other areas http://dmh65.smugmug.com/photos/i-M7...M7pLKsC-X2.jpg http://dmh65.smugmug.com/photos/i-2n...2nXtWpf-X2.jpg http://dmh65.smugmug.com/photos/i-W3...W3J7FB4-X2.jpg http://dmh65.smugmug.com/photos/i-BT...BTqsFDC-X2.jpg also repainted the swingarm *********the bike is going to a show to be displayed and just in case the new one doesn't arrive i have to make it look good in the mean time*********** http://dmh65.smugmug.com/photos/i-hJ...hJN5b4n-X2.jpg this is the swingarm pivot bolt, it needed cleaning too! the dirt around it is what was packed into areas that when i cleaned the bike i couldn't get to, it was made up of hard packed grease and dirt, time to break out the wire brush http://dmh65.smugmug.com/photos/i-rp...rpWgQfk-X2.jpg |
the Ohlins suspension in place
http://dmh65.smugmug.com/photos/i-9m...9mZgVL5-X2.jpg it is a very tight fit, very tight!! i am currently working in a CNC and machine shop so i made some 'jack up links/ dogbones" they are the ones on the left, they are made from 304 stainless steel, and 115mm long, only one problem, they don't work with the Ohlins. the spring body is larger than the stock one so the Ohlins hits the swingarm, the longest that will fit will be 125mm long, i'll make some more so if anyone wants these for 35 pounds including shipping send me a PM http://dmh65.smugmug.com/photos/i-H7...H79xffh-X2.jpg here it is together, all cleaned off, repainted, regreased, loctite on all the nuts and bolts http://dmh65.smugmug.com/photos/i-JX...JXjMg6b-X2.jpg to do the swap took me about one and half hours one thing i didn't get a photo of was an adjuster on the inner side or the right hand frame, it is threaded and there to stop side play. How i put this together was using a long piece of rod about half the size of the pivot bolt, this way you can get it in and out easily to make adjustments for width, when it is a snug fit with virtually no side play then i put the pivot bolt in, greasing it first of course, then add loctite to the nut on the left side http://dmh65.smugmug.com/photos/i-jm...jmV4D9N-X2.jpg also i added a toe guard, i was ridden off the road in Bolivia and thrown from the bike but my foot got caught under the bags and the tip of my boot caught the chain, this is to eliminate that happening again 'if' i come off...just my personal preference also i added a new upper chain roller you can see in this photo, the old one was absolutely destroyed |
That swingarm wear is proper scary fella.
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Because its cast it can't be welded and machined, it would anneal it |
Thanks Paul. A really good read and nice photos. You've done a cracking job getting the bike refurbished ready for the next leg of your trip.
With the top roller mashed and the swinging arm grooved on the bottom would seem to suggest that you rode a large chunk of your 50000 miles (sorry 50001 miles ;) ) with the rear suspension pretty much bottomed out? I can see why you were looking at raising links now. I'm sure the Ohlins shock will help with this, the Sachs spring must have been well saggy (they don't generally make 10000 miles!!) |
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i even had the suspension set at its stiffest point, it was the only adjustment i could make |
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next is the MTC exhaust
the stock exhaust was harder to get off than the new one was to put on...the retaining bolts on the exhaust clamps had rusted solid so had to be snapped to get them off. I replaced them with nickel plated grade 8 so it won't happen again.
the stock rear exhaust hanger is replaced with the new unit, i'm doing a single stainless can, ordinarily you would cut the other side off if its not being used to hang an exhaust but i am contemplating making an auxiliary fuel tank in the space left by the right can once the stock system is taken off you can see the heat resistant pad which is silver colored, i sprayed it with hi temp black paint to help it disappear a little but still have the same effect if required to protect the electrics http://dmh65.smugmug.com/photos/i-Dp...DpRqBG5-XL.jpg http://dmh65.smugmug.com/photos/i-wH...wHfzLDt-XL.jpg http://dmh65.smugmug.com/photos/i-Z8...Z8FFS7c-XL.jpg before the rear wheel went back on i did the kev mod on the cush drive rubbers, it looks oily, its not its soapy water to help it slide together easier...oh, and by the way those cush drive rubbers have 40,000 miles on them!!! http://dmh65.smugmug.com/photos/i-FB...FBJ3C4C-XL.jpg http://dmh65.smugmug.com/photos/i-Pz...Pzz4Kmz-XL.jpg http://dmh65.smugmug.com/photos/i-nT...nTkHHFB-XL.jpg http://dmh65.smugmug.com/photos/i-WK...WKh4z6N-XL.jpg http://dmh65.smugmug.com/photos/i-QX...QXdGhxM-XL.jpg just realized i forgot to mention tyres...i did a front tyre change to match the rear, the front has zero miles but the rear has 6000 on it, Kenda K270, i did maybe 2500 miles off road...the wear is good but they are a bit noisy on the tarmac, but cheap - pros and cons!!! http://dmh65.smugmug.com/photos/i-bt...btjFgq6-XL.jpg http://dmh65.smugmug.com/photos/i-g8...g8Chvsk-XL.jpg ...and if you are wondering what the white patch is on the left side of my tank it a customs sticker from flying the bike bike from columbia to panama, it looks like $hit but kind of reluctant to take it off |
chain guard and headlight guard fabrication
had some spare time this week so when i found a crack in the chain guard it was time to make a new one
took a template from the original trimmed some aluminum sheet to size and bend it in a sheet metal brake http://dmh65.smugmug.com/photos/i-sK...sKDXXVV-XL.jpg drill some holes and used a dimple die, they look like this http://dmh65.smugmug.com/photos/i-63...63Fc65P-XL.jpg http://dmh65.smugmug.com/photos/i-g5...g5qwRZd-XL.jpg so basically lightened it up a little but the dimple adds strength to the piece this is what it looks like against the original...not sure if i like it or not, or if i need to paint it black, or add another hole or more in the "V" area http://dmh65.smugmug.com/photos/i-tj...tjx7Fkv-XL.jpg http://dmh65.smugmug.com/photos/i-dW...dWkQgNj-XL.jpg http://dmh65.smugmug.com/photos/i-gc...gcF5zzk-XL.jpg got this finished quicker than i thought so i had a template for the head light, so started to make a rock guard, with the XTZ headlight being a complex shape it was easier to make a generalized shaped around the template http://dmh65.smugmug.com/photos/i-zZ...zZC9P72-XL.jpg http://dmh65.smugmug.com/photos/i-jg...jggq27R-XL.jpg http://dmh65.smugmug.com/photos/i-BF...BFskZdC-XL.jpg http://dmh65.smugmug.com/photos/i-cR...cR5VhMk-XL.jpg http://dmh65.smugmug.com/photos/i-hZ...hZ7MmnP-XL.jpg in the last photo you can see another one i was making as well...choices???? |
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