Cheers

Update time.

Did this a while ago but only just remembered/had time to post it up here.

Fork refresh

Not having a garage anymore is lending to me using my accommodation probably not as intended. Ian if you're reading, look away now!




So I made use of the block's utility room (which no-one uses anyway), and set about stripping my forks in there.





The oil was all grey and metallic and minging, more proof they needed doing....

The bushes were quite worn but I was going to replace them anyway along with the seals and oil.





Had a bit of a mare with the damper rod and managed to squirt myself in the eye with oil from it when pumping out the air. But other than that it was pain free.

Another job jobbed, just need to get the suspension set up properly before two days at cadwell park. Unfortunately not with you lot, but with the OMCC, two days for £165 you can't moan!

Next on the list is either new rear-sets or riser plates, single seat cover/conversion, then finally onto the cosmetics (if track days don't pinch all my money, caught the bug!).

Well I haven't gone down the route I mentioned in my last post, no rear-sets or single seat conversion.

But I have done a few little bits with more to come after Christmas.

I moved base again in October and the motorbike club here has a fully outfitted workshop, big win

Got the bike up onto the ramp and started stripping the front end ready for a new clock/headlight bracket, screen brace and modification to the speedo bracket I made a couple of months ago.



The bracket needed lowering on the mounting to allow the clutch to clear properly as before it was catching and nudging the clocks. Luckily the club have a pillar drill, but unluckily they don't have a small handheld vice so mole grips were put into inappropriate use....



Nose cone back on and checking for clearance.





Then I changed the screen brace for a lovely SES aluminium one as I'm becoming a bit of a tart....



On and checking to see that everything lines up as it should.



I also got myself a hydraulic conversion off a member on here (can't remember who sorry!)
It was as expected a bit grubby as it'd come off another bike, so once I'd dissembled and cleaned up I could see what if any parts I'd need to order.





Iv'e ordered a new gasket to go between the slave unit and the sprocket/clutch cover, a new o-ring seal for the slave end of the clutch push rod, plus a couple of bits for the m/c which I'll come on to later.

All cleaned up I re-assembled the slave unit with a good layer of rubber grease and it slides lovely now.





Unfortunately when it came to making sure the bleed nipple actually moved it just didn't. And it snapped



So back to using the pillar drill again....

I unbolted one of the vices from the bench and just about made it work under the drill.



All drilled out I pulled some of the thread spiral from the nipple out but had to tap the rest.



Next job was to shorten the VFR750 clutch push rod I had to 339mm as per the clutch conversion thread.



3 junior hacksaw blades later and this tough bugger was finally cut.



I made use of yet another of the clubs tools and created a rounded edge after the cut to prevent damage to the slave seal.



Here's the difference between the two rods, the NC30 one being shorter.



Fitted up the slave cylinder onto the cover and connected up my new Hel line (matches my brakes, I know, tart).



I then attached the SP2 m/c to the left bar and connected up the other end of the line. I am still waiting on a new reservoir cap, lever, lever push rod and bush, plus the gasket and seal before I can bleed up the system.
I didn't take any photo's of the m/c as I forgot but after Christmas I shall have a lovely set of CNC adjustable levers and SES aluminium clip-ons to finish it all off

One last job was to balance the carbs as the idle was a little rough, luckily the club also has a carb balance kit! Brilliant place this.





Didn't get a pic of vid of me actually balancing them up as I was too pre-occupied with the engine gently roasting my right hand while adjusting the carbs.

Other update is that I have removed the alarm from the wiring loom as it was causing a 7A drain on the battery.
The difference to the bike was very noticeable after I had taken it out, started easier and ran better. Plus it doesn't need to be left on charge anymore

The bike will be staying in the dry and slightly warmer than outside club garage until the spring when I get back on some more trackdays!

Next will be finishing off what I have mentioned, fitting some wet tyres to my newly acquired spare set of wheels, spacing over the chain so I can run 160's and maybe a Q/A throttle.
I might even get round to that single seat conversion....

Now Christmas is over I had some new bits to fit onto the bike, and some parts to finish off previous work.

First job was to do was to fit my new SES clip-ons, so out with the front wheel to be able to drop the forks.



I got each clip-on fitted, shortened the throttle side one, fitted my new cnc'd adjustable levers,a brake lever guard also from SES, a new clutch reservoir cap and filed down the locating tabs on the throttle housing and kill/starter switch gear. With them fitted the clearance when turning the bars to the clocks was fouling again, so with some small tweaks I managed to get it all just to clear.





I haven't cut the left side down to size as I'm yet to fit the new grip.
Also I'm now waiting on a HRC Q/A throttle from Rick O to replace the standard one.

Next was to fit the new clutch slave cylinder gasket and push rod seal.



After that I bled it all up and tested it. Working perfectly with a nice feel for the bite point too

When I first wheeled the bike around the club garage to get it onto the ramp I noticed it had been leaking a small amount of oil on the floor over Christmas, bummer. On investigation it looks like the waterpump seal has gone and is very slowly leaking.



It also looks like the rear cam cover gasket is leaking a bit too, so I'll whip that off and inspect it. Hopefully it just needs re-seating.



I'm now just waiting on some parts from Rick, and should be picking up some wet tyres this weekend.

It's all go before March when I've got my first trackdays of the year booked

You coming to Cadwell this year?

For the classic bike weekend?

I should be, I can't see work getting in the way too much as I'll be back in training for a year in April.

Just depends if the Cosford Air Show clashes I guess...

So this is all of this weeks exploits in the time between waking up and starting a night shift....

I got my recently acquired wets stuck onto my spare NC35 wheels which I snapped up in a good deal last summer, and fitted some stainless captive spacers from Rick O.





Love the rim tape....

Next was to change that leaking water pump seal. Off with the sprocket cover, drain the cooling system and out with the water pump.



I got the pump body into the parts washer as it was fairly grubby and then had a good look at the seal, which as you can see was pretty buggered. Flattened, brittle and hard. Not what you want an oil seal to be!







So off with that manky seal it was, and on with a nice flexible fresh new one. Plus a new pump cover seal too.



Back in with the pump and I finally realised after 4 years of ownership.... that there was a bolt missing on the waterpump not allowing it to be properly held into the engine.

So in went a nice shiny stainless bolt with some of my new favourite graphite grease on the end of the threads.



Whilst I had the sprocket cover off (even though it's cut) I decided to fit the chain spacing kit from Rick O. One goes behind the front sprocket, one on the sprocket bolt and one in the rear hub where the seal is behind the sprocket carrier.







When I un-staked the hub nut to remove the sprocket carrier, the previously staked part just decided to decimate itself. It's a drilled titanium nut so instead of re-staking in its new position after having the spacer fitted (which would just amount to it destroying itself again) I decided to drill the staking slot on the rear axle and will fit a split pin in there when I have robbed a suitable one from work



As the cooling system was still drained I changed the fan casing bracket thingy to a stainless steel item I have had sat in a box for a while. Much nicer



After re-fitting the sprocket cover, re-filling the cooling system and burping it I had time left to fit the HRC Q/A throttle I also received in my latest box of goodies from Rick O



Quite a simple bit of kit really. A new larger throttle housing, tube and two new screws complete the kit. I used the same standard pull throttle cable (I don't run a return cable) as per Rick's advice, and fitted the new throttle grip too.



I also had a new grip for the other side so that got slid on. Both grips will be lockwired tight next week when I have also robbed some lockwire from work along with the split pins.



I fitted back the bodywork, and stop drilled a couple of cracks in the screen. The only thing letting the cockpit, as it were, down now is the scruffy top yoke. I would source a powdercoated one or get mine done but my yearly car insurance payment has just emptied my bank account and I need to buy new 090's next month as well as pay for a holiday







I mentioned the weeping rocker cover seal in the last update and it seems they have both finally stopped sealing effectively after 23 years on the bike, so 2 new ones will get ordered when I get paid. As will a crankcase breather filter, as it seems as though the higher rev track riding I do more often now is pushing more oil through to my airbox and I don't like that.

After the lockwire, split pin, rocker gaskets and crankcase breather the bike should be ready to rock and roll for the track days I have booked in March

Not much has happened since the last post, other than I got paid and ordered the gaskets and filter. Oh and I bought a new bike which I'll be picking up Sunday. Nowt exciting, just a XJ900F to do 400 miles every weekend when I move again, should be quicker than the car in Friday rush hour!



Whilst I've had a bit of time and the weather has been fair I took the bike out for a ride and it was nearly faultless.

Only thing was the clutch reservoir likes to leak out the bottom where it meets the master cylinder. I think a small o-ring is at fault so that's been ordered too. Other than that the bike was ace and so were the roads round where I'm currently based, if a little dirty!

After the ride I finally managed to get the bike onto my trailer to test the wheel chock I put on it a few weeks ago. Makes loading a lot easier as it's solid in the chock. Not wobbling all over the place while I try tie it down like before.



Final thing is today I got time to wash the bike for the first time in months. It's annoying that the club garage doesn't have a tap at all otherwise this would have been done much sooner!



Just waiting for a few parts now. I've already got some new 090's in 160/60/17 and 120/70/17 so they match my wets in size. Going to finish off the old ones first though, no point wasting them. Then after that I should be all ready for two days on track in March!

Just read the full post as I'm thing of getting a VFR soon.
Thumbs up pal great work and have given me plenty to think about.

Cheers, it's been a journey and has frustrated me at times, but it's so worth it listening to that happy V4 howl round a track with me on it!

Been meaning to post this, finally got round to it...

Managed to get the new rocker cover seals, also got a new set of clutch reservoir seals and a crankcase breather filter.

First was to strip the bike to fit the new rocker cover seals.





Not wanting to drain the cooling system I had a mare with the front rocker cover having the top rad in the way instead



Whilst putting it all back together I fitted the new crankcase breather filter and blanking cap for the airbox.



Last but not least was to fit the new reservoir seals to stop it weeping hydraulic fluid everywhere...



After all this it's ready for the track season and a good thrashing