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Done very little lately - lacking a bit of motivation due to not having body
work, however collected everything this evening. Looks great considering
price - couple of small marks that I would have mentioned if I’d been
paying full for it, and colour is a fraction darker than I would have chose
but considering the budget for the bike I think it will look really good.
10th March 05 1 1/2 hours
Had footrest plates dismantled at work due to all the pins being seized.
Drilled out and tapped a couple of rounded bolts and sprayed foot rests,
mounting brackets, mounting washers, and anything else that would
show. Cleaned mounting plates. Footrest rubbers purchased
11th March 05 1 hour
Cleaned all plastic and fairing parts
12th March 05 2 hours
Reassembled footrests and started fitting exhaust.
13th March 05 5 1/2 hours
Finished fitting both footrests, exhaust and exhaust shield. Reassembled
rear brake master cylinder and bled brake. Loosely assembled front
callipers and bled front brakes. Drained final drive and filled forks,
gearbox and final drive with correct oil. Fitted petrol tank and connected
fuel lines. Added fuel to tank and noticed slight leak at side and under
tank. Decided as leaks were slight that I would see if bike started only to
find that I had no circuits responding other than the side lights. Removed
fuel tank and checked leaks, the one under was from the sender
mounting plate and should be simple to cure, the one on the side
appears to be a result of the preparation for spraying but can be
repaired with petro patch. When studying the wiring diagram later it
seemed the only common circuit was the earth under the tank but I had
already checked that. Closer inspection of the diagram showed an
auxiliary position on the ignition switch. I suspect that this was where I
had turned the key to, suggesting the ignition is sticky or I did not turn
the key far enough due to unfamiliarity.
17th & 18th March 15 hours Photos 74 - 80
Had 2 days off work to carry on and got the bike fully assembled, the bike
would not start and only had sparks on 2 cylinders so after checking I
ordered an 2nd hand ignition trigger. The seat base was also resprayed
and all fairing brackets were repaired or re worked. Although 2 days was
spent this was the time consuming jobs like cleaning and re gluing
badges and other cosmetic parts.
26th March 5 hours
Fitted new trigger and bike started straight away although did not run
quite right - seemed almost on 3 cylinders.
28th March 1 hours
Had bike MOT’d - no problems but still not running right.
I spent approx 5 hours over the next few days
I checked and changed 2 injectors and tried tuning before accepting that
one of the new plugs could be faulty, once changed the bike has run fine.
I would like to get the gearbox and final, and the wheels powder coated
black soon and a new set of tyres would help the handling, I also new to
get a fairing panel resprayed after a minor incident on the drive. The bike
has now done about 350 miles and I consider the project finished apart
from routine maintenance and the bits already mentioned.
TOTAL TIME SPENT WAS 115 ½ HOURS AND THE TOTAL COST WAS
£869.14
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