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1st February 05 1 1/2 hours
Drilled out seized mudguard mounting bolts on front forks and removed stanchions. Removed dust caps and oil seals. Cleaned and refitted rear suspension unit. Resprayed fork sliders.
4th February 05 2 hours
Fitted new head bearings and cleaned bottom yoke. Cleaned handle bar clamps and fitted spare bars. Replaced rear wheel and fitted new oil seals to fork legs rebuild legs and fitted into clamps, cleaned, sprayed and fitted front axle and wheel. Able to wheel the bike about again for the first time.
5th February 05 3 1/2 hours Photo 66 - 69
Cleaned all parts before fitting, parts fitted to day were, alternator, starter motor, top air box and air filter. The top air box has the air flow meter and part of the engine wiring loom therefore the injectors, throttle potentiometer and temperature gauge wiring was reconnected. The handle bars were also stripped and these and the bar end weights were resprayed.
10th February 05 1 1/2 hours
Handle bars and controls refitted. Main fairing bracket refitted and control cables reconnected and adjusted.
11th February 05 1 hour
Main wiring loom and relay box refitted. Wiring will need sorting as connectors seem in wrong places. Had to stop early due to standing on a screw.
12th February 05 1 hour
Wiring loom re-routed and correct connectors identified. Battery clamp refitted using studding and battery connected. Clock worked but no power when the ignition was turned on. Checked back form the battery and found power to fuses ok but not getting to the multi plug that joins the ignition switch wiring under the tank. Fault appeared to be in the loom so a new wire was run from the battery side of the starter relay and soldered to the pin on the multi-plug, the old wire being cut and taped at this end. after reconnection all circuits appear to work as much as could be tested by temporarily reconnecting lights and things. Engine turned on the starter motor for the first time. Fuse box and storage tray covers refitted and frame covers either side of the steering head. I am getting to the stage where I need the body work back from Cowlins.
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Jobs left that can be done are as follows
- refit radiator and fan (hose clips needed)
- refit plenum box
- fill engine, gearbox, final drive, cooling system and forks
- clean drill and retap bolts and refit exhaust
- clean and spray footrest plates
- bleed brakes
- fit rear mudguard.
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13th February 05 1 hour
Refitted Radiator and filled cooling system, filled engine with STP left over from assembly and oil
17th February 05 1 hour
Cleaned exhaust pipes and finished details and mounting holes for silencer cover. Sprayed cover ready for assembly. Fitted new breather pipe
19th February 05 3 hours
Fitted plenum box with new clips ordered from motobins along with exhaust clamps and footrest rubbers. Fitted various wiring ties and Sprayed and fitted all secondary fairing brackets.
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