The new axle fits into the NC30 hub eccentric, but while I had it apart I checked things out. I had a little rock garden on the inside of the swingarm:



.. and no bloody wonder the hub has been difficult to adjust .. the surface was all crapped up. The dremel will fix that. :-)



An initial fitment goes well. The NC30 sprocket holder fits perfectly also:





.. but this looks a but sticky outy. I had to use new bolts here and maybe .. just maybe they are too long ...



.. yep. When I try to fit the wheel ... too long. Bollocks.



Typically, the right length was not an off-the-shelf length, so I cut some bolts to fit. The left is the 400 bolt, the right is new bolt, and the middle is a cut-down bolt to fit:



Perfect:



And the fit seems okay:





.. and doesn't this make you want to go fast .. :-) (yes, the rear subframe is bent!)



continued ...

Let's get some forks on then.

All done and and ready to install:



Yep ... here we go:



Oh .. f*ck boll*cks sh*te. Now that the forks are straight, it shows that the triple clamp is bent. B*LLOCKS!!!

This ain't how the front axle is supposed to go ....



<grabbing for wallet> new lower triple clamp required.

continued ...

okay, so lower triple clamp is screwed. These bearings are bloody expensive, so I thought I might try to get the old ones off. They still looked good:



Flambe ...



But .. I had no joy and so bought a new set of bearings and races. The old races felt smooth enough, but when I got them out and cleaned them up and *then* ran my finger nail across them (this is the lower) ...



.. not so good. Best to replace.

So, I got a new triple clamp lower and removed the bearings with the dremel:



and I just couldn't bother being gentle with the bearings on the 'new' triple clamp, so I dremelled them as well and then heated. The came off okay after that:



.. but I did do some slight damage to the stem .. which some wet and dry smoothed out ..



So, now to try and get the new bearings on the new triple clamp lower. Geeez. What an effort. Really.

Here it is cooling down with the (real) dog bones:



and then using an old fork stanchion I had around, trying to pound it in with a hammer and block of wood atop the stanchion:





it did not want to go further than this:



.. but after some quite (f*cking) vigorous smacking I got it down:



I had a beer after that.

The inner of the clamp was mucky:



so armed with my newly received 30 units for $10 dremel abrasive buffs (which I love):



we go to this:



And same for cheapie dremel wire brushes ...



to



continued ...

Okay then we've got a new triple clamp lower with new bearings and races fitted all around, time to see it it all line up:

... and the angels sang!



still on blocks, but cooling system now fitted. I bent my new chinese upper radiator in the crash, so for now, the old one is fitted back on.



This was the oring on the temp sensor unit. I got a new one but geeez:



Top triple clamp bracket and clipons back on to allow pushing it around:



... and talking of pushing it around, I got this to be able to (while in garage) just leave it somewhere for a moment without a rear stand:





Okay, two wheels on. Front wheel stand on and wooden blocks removed. At last!!



.. and finally lowered to the floor:



.. wheeled outside .... and now ...



and empty space in the garage!!! ... but guess what is waiting ...



finally. Bike is rolling, space is cleared and it is now on the lift. Lift? Yes, seems a bit of an overkill you might think but it is simply the best bit of kit in the garage. I have a poor back and this saves it. As an alternative to laying on the floor, this means you can do so much more on your bike(s). It'll cost you $500 or so, but that is only 5 hours motorcycle mechanic labour around here. Easy.





continued ...

Great progress mate, reminds me of overhauling the heads on mine last year, really satisfying to hear it fired up for the first time after doing so much work!

Watching

Great write up, keep it coming..
I brought a lift years ago and it's one of those things that once you have one you don't know how you manages without it.

Had I seen this thread a few days ago, I would have offered one of my spare sets of carbs to you, I have a complete spare set and a set for parts, so If you need anything just let me know, im always keen to help out a fellow racer. I also had a similar stack at Morgan Park raceway in QLD last year, actually cracked a head and filled the bike with rocks.

Thanks edditk7,

I may need them yet! So don't go selling 'em yet. :-)

I stripped the 'new' carbs today and uh-oh. Not too sure about this. All four top chambers were a bit like this:



I am learning ... if it comes from Japan, it is highly likely to be corroded (bikes live outside, and I understand they have more acid in their rain than we do).

Anyways, I did give one on a cleanup with the dremel. Before:



after:



And it has come up sort of okay, but I left wondering what corrosion there is that I can't see.

Any thoughts out there? Should I be giving them back and getting another set?

All help appreciated.

What bit are you using in your Drexel for cleaning up like that? Removing carbon etc.