And so it begins.......... Mk2 rebuild

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knackeredMk1
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Re: And so it begins.......... Mk2 rebuild

Post by knackeredMk1 » 15 Sep 2011, 21:49

Moving on :) .

Looks like the fork bushes need to be replaced. Bare copper - not so good.

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Re: And so it begins.......... Mk2 rebuild

Post by Hallsy » 15 Sep 2011, 21:53

Trying too!! Trying to keep it paced otherwise I'll spend too much too quickly (trying to keep overall spending from getting excessive!).

I did wonder about the bushes, but I must admit I have not looked at them since I stripped them as I still need to thoroughly clean the lowers & internals. Should have added a pair to my David Silver order :oops:

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Re: And so it begins.......... Mk2 rebuild

Post by back off road » 15 Sep 2011, 22:00

Hallsy wrote:Trying too!! Trying to keep it paced otherwise I'll spend too much too quickly (trying to keep overall spending from getting excessive!).

I did wonder about the bushes, but I must admit I have not looked at them since I stripped them as I still need to thoroughly clean the lowers & internals. Should have added a pair to my David Silver order :oops:
;) sorry Hallsy but its gonna get expensive
Im thinking about a bike with more valves than a powervalve

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Re: And so it begins.......... Mk2 rebuild

Post by Hallsy » 15 Sep 2011, 22:05

Well, hopefully now I will only have to spend out money on the engine, apart from tidying little bits here & there. If I decide to start uprating bits, or blinging the bike up then that will come later once it has been rebuilt to a (hopefully) reasonable standard.

Nack - I'm guessing it's advisable to replace the bushes in pairs? Any reason not to trust aftermarket? Wemoto have the inners for ~£8 each and the outers for ~£3 each. LT want ~£50 for a bushing 'kit'.

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Re: And so it begins.......... Mk2 rebuild

Post by fallenmikethebike » 15 Sep 2011, 22:24

Not replacing the bushes would be a false economy,as the seals will inevitably blow again.
Mike
VFORCE REEDS-MUGEN HEAD AND BARREL-WHITE POWER-ALL ON MY WISH LIST!!

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Re: And so it begins.......... Mk2 rebuild

Post by twistednuts » 15 Sep 2011, 22:26

I planned on spendin 200 quid max to get mine sorted......

Over 600 quid later an i finished it :D an i didnt even get the frame coated!! Mainly cos im a tight ass

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Re: And so it begins.......... Mk2 rebuild

Post by knackeredMk1 » 16 Sep 2011, 07:26

My Mk1 cost me a little under £6k in total :!: .

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Re: And so it begins.......... Mk2 rebuild

Post by Hallsy » 16 Sep 2011, 11:13

:OMG You must have bought everything from LT ;)

Well, I don't think my rebuild will be anywhere near as extensive or polished as yours, but I reckon I will spend around £400 on mechanicals by the time I've finished and I paid £350 for the bike (or should that be bits!!??).

I'm logging what I spend. I'm lucky that I can save money by making bits where necessary, or having suitable bearings/seals laying around.

Head bearings are next, thought I could get away with cleaning & regreasing, but the races are a little tarnished in places and removing the lower one for cleaning will be near on destructive, so I've ordered a new pair.

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Re: And so it begins.......... Mk2 rebuild

Post by Hallsy » 18 Sep 2011, 20:05

Finally got my heavy duty paint stripper through on Friday, so tried some on my fork uppers. It worked well, but unfortunately the uppers are in quite a sorry state underneath. A few scuffs & scrapes, uneven shade of anodising, so unfortunately I will have to paint them again. Probably go with the same satin gold that I'll repaint the engine casings with, will have some pics tomorrow as I've not done anything with them all weekend.

Other than, I'm still waiting on bits from David Silver. Doesn't look promising for 7 day delivery as I ordered them last Tues and it still says they're on backorder :(

New rear wheel bearing retainer has been made:

Image
2011-09-17 18.16.54 by Hallsy01, on Flickr

Been out & about this weekend so nothing else going on, will crack on prepping fork uppers and flatting swingarm tomorrow.

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Re: And so it begins.......... Mk2 rebuild

Post by back off road » 18 Sep 2011, 21:43

tidy bit of engineering hallsy ,wish i still had access to the work lathe and miller
Im thinking about a bike with more valves than a powervalve

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Re: And so it begins.......... Mk2 rebuild

Post by twistednuts » 18 Sep 2011, 23:23

knackeredMk1 wrote:My Mk1 cost me a little under £6k in total :!: .
:OMG How is that even possible? No wonder your reluctant to sell it!

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Re: And so it begins.......... Mk2 rebuild

Post by Hallsy » 19 Sep 2011, 09:28

back off road wrote:tidy bit of engineering hallsy ,wish i still had access to the work lathe and miller
I can't take credit for that unfortnately, a workmate of mine offered to make one as he didn't have much on!! It is very handy having machining equipment around, unfortunately I don't get to use it much anymore (not within my job role), but a while back the company created a toolroom to start making more parts in house again (fixtures, repair parts, etc) - but then this disbanded and the guys from the toolroom joined our engineering maintenance department, so they still get involved with a lot of machining work. As I say - handy ;)

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Re: And so it begins.......... Mk2 rebuild

Post by Hallsy » 22 Sep 2011, 22:23

knackeredMk1 wrote:Moving on :) .

Looks like the fork bushes need to be replaced. Bare copper - not so good.
Got the Mk3 bushes through today from Wemoto, not 100% that they are both right, looks like one might be a little larger than Mk2, but I'll find out tomorrow when I remove the old ones and measure them.

One thing though, the bare copper you mention Nkd, that is on the outer of the bush, not the wear surface. The inner one that is seated in the recess is still grey (coating applied to copper bushes), and the inner on the outer one is still grey also. Still, won't hurt to replace them if these ones are right.

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Re: And so it begins.......... Mk2 rebuild

Post by Hallsy » 23 Sep 2011, 21:34

Yep, looking again at the fork bushes I'd say they look totally fine, no obvious signs of wear on the friction surfaces, but that's my fault for ordering new (wrong!) ones without having a proper look.

Scuffed uppers have been filled and one of them pretty much prepped, will hopefully get these finished & painted tomorrow.

Yesterday I decided I would get the swingarm powder coated. The original anodising was worn in places and to get it uniform I used a flap wheel in a drill, which worked really well, but couldn't quite get in all the nooks & crannies, and unless you had a very steady hand, the brush lines were not perfect. I wasn't looking for something perfect, just uniform, but it would need protecting. I'd figured I would give it a couple of coats of 2K lacquer, but unfortunately it won't ahdere very well unless I use an etching lacquer, which is pretty pricey apparently. So I ditched that idea and will be getting it powder coated. Satin black or satin silver, undecided so far!!

I'd mentioned before the small crack where the dust seal fits on the bearing housings. Welding was discounted as unsure about it messing with any production heat treating, that and it would be a bit thin to make a decent job of. So as the bearings will support the inner, I decided to use a cap in place of the Honda dust seal to support it exteranlly and help prevent cracking. I'll use something like Loctite bearing retainer in the crack and between the housing and the cap.

Here's the small crack (sorry phone pics again as was at work!):

Image

And here is the original dust seal next to the cap I'll use:

Image

And in place:

Image

Also made up some new bearing sleeves for the swingarms as I didn't have the originals, but these are being heat treated at the moment. Got my swingarm pivot and few other bits through from David Silver now, so once the swingarm has been coated it will be ready for rebuild.

Also painted the linkage and dog bones:

Image

Moving along...........slowly!!

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Re: And so it begins.......... Mk2 rebuild

Post by Hallsy » 23 Sep 2011, 22:30

Tonight was quiet so I decided to try to clean up the shock a little, which then lead me to stripping it down!! I know I'd been advised to leave it to suspension experts, but I had to have a look!!

I'd already disconnected the resorvoir as there was no nitrogen in it, and it was leaking oil from the banjo due to a missing copper washer.

The spring seat was caked in mud, grease and rust. There was no way the seat was going to 'tap' away from the centre piece and spring clip. Some Plus Gas and a hammer & drift sorted them out!! Looks like the two parts had rusted together so cleaned them up with a wire wheel, fit together nicely now.

Removed the bladder from the resorvoir, looked to be in good condition, but I have not yet pressure tested it.

The fun began when I started to strip the shock body. Seal head was tapped down and circlip removed, but trying to pull the seal head out wasn't too easy, the o-ring gets stuck in the recess for the circlip and needs quite a bit of force to remove it. I didn't have a slide hammer to hand, so decided to put an air fitting in the shock body and pressurise it force the seal head out. 6 bar later and the seal head was slowly moving, unfortunately I didn't fully consider how far the shaft would 'fly'!! Yep, the shaft went flying across the workshop into one of the doors!! In hindsight I should have rigged up something soft or something to catch it. Reassurlingly a workmate said when he did his 'it just popped out and slid across the bench'!!

Anyway, internal looks OK, but unfortunately I have damaged the piston slightly, so will need to source a new one. I've contaced a few suspension specialists to ask about serving costs, etc, but if spares are available I'll probably replace the o-ring and dust seal on seal head and the piston that I've damaged. Refill with oil then take it to a specialist to have it re-charged. I know that a specialist would be able to adjust the shims & piston to suit weight and riding style, but as I'm a total newbie I'm not convinced I'd know any better at the moment.

I'll replace the hose as well, it's not damaged as such, but it pretty hard & tired looking!

Anyway, shock stripped down (I'd put the bladder back in at this stage):

Image
2011-09-23 20.49.08 by Hallsy01, on Flickr

and the damage I caused :oops:

Image
2011-09-23 20.49.16 by Hallsy01, on Flickr


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