The rehabilitation of Sir Gustave Sabastian (‘Gus’)

Discussion in 'New Zealand' started by Box'a'bits, Aug 22, 2010.

  1. bart-nz

    bart-nz Been here awhile

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    Weather looks OK Friday/Saturday, but we may get a wet arse Sunday.

    I don't care. I just want to ride.
  2. Box'a'bits

    Box'a'bits In need of repair

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    In keeping with the last minute prep for this weekend, pulled the fork to pieces last night to swap the bush stop around. Got fork oil everywhere, & didn't mop up thoroughly enough, so got pinged for it at WoF. That & the hyper flashing indicators.

    Just getting to VTNZ was a drama, because there was no one able to do it at Thorndon & I had to ride to Adelaide Rd in rush hr traffic. I was the last inspection of the day. The guy was thorough, to the extent of checking the spokes.

    Not a word about the brake lines (which are legal but VTNZ tends not to like), nor the fork swap, nor the supermoto brake.

    So I guess I'll be riding w/o a WoF this weekend, will remedy the hyper flash Monday (I've the day off) & re-do the WoF after that. I expect that the forks will be fine once I've cleaned them properly.
  3. advNZer?

    advNZer? Long timer

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    why the hyper flashy indicators...have you got some little dinky led ones?
  4. Box'a'bits

    Box'a'bits In need of repair

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    Nope, KTM 10w ones. Down from the 21w stock. I replaced them because the front stock ones disappeared with the GS fairing woolly mammoth head, the rears ones were shitty chinese ones.

    The flasher thinks there is a bulb out. That's why WoF don't like hyperflashes. It supposed to indicate that you need to replace a bulb.

    Technically I am also missing an indicator idiot light too.
  5. Padmei

    Padmei enamoured

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    I just bit the bullet & bought a properer flasher unit. i think it was between $30-50 bucks.

    I'm not joking after watching those frickers flash so fricking annoyingly fast it was beautiful fitting the new flasher & having them flick away at a nice realxed pace. Somedays i would just go & ride to watch them do their thing.
    I still get a buzz out of seeing them going on & off on & off


    Ahh the simple joys in life
  6. Box'a'bits

    Box'a'bits In need of repair

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    I'll just wire in some resisters. I've had some for ages. The bikes been thru' 2 VTNZ WoF's with no issues. I think he tacked the indicator fail on just because he decided he wasn't going to pass the 'leaking' fork seals.
  7. innathyzit

    innathyzit AKA Woodman

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    Not Airhead I know but relevant-ish fyi.

    I got 10w bulb cheapies on the back and leds on the front which the genuine kwaka flasher found bewildering, but a thermal flasher works perfectly which everyone told me wouldn't considering the bulb/led mix.Less messy than resistors too I reckon.

    You can watch me flashing next time we go on a ride Padmei.

    Also, did you fail on the non indicator idiot light? What if you can see your indicators flashing when you are riding?
  8. Box'a'bits

    Box'a'bits In need of repair

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    Text heavy write up - I took bugger all photos. Hopefully I can steal from others.

    The weather for this ride wasn’t looking too flash.

    I took time off late on Friday afternoon to get a WoF for the bike. I’d needed to do some work on the bike prior, & because of a delay in getting the parts in, I was rushing to get the bike together after attending a work function. The moral of the story is don’t work on the bike when you are not umm…firing on all cylinders. I missed the WoF with a leaking fork seal (just replaced these & the bushes) & hyper flashing indicators. I was the last inspection for the day. The inspector didn’t comment on the YZF forks or the brake lines as expected.

    Up at 6.00am to leave by 7.00am. Unfortunately when I bravely peered out the window, it was already raining. The Metservice real-time data indicated it was raining at Paraparaumu & Palmerston North. Fortunately it appeared dry in Masterton, but it meant I needed to ride the Rimutakas (what a chore)…but that way is also slightly longer time wise.

    By Pahiatua it was obvious I was late (it was already 9.00am), but I figured I had enough gas, & I thought I’d meet the guys coming towards me if they left on time. That wasn’t to be. Got to the Woodville meeting place to be told 5or 6 bikes left 5 or so minutes ago.

    Okay the other meet point was the Makairo track itself. Should I ride thru or go around & meet them on the other side. What to do.

    Gerard was waiting at the Mangatainoka turnoff on his R1100GS hybrid (I think he’d been looking at the rally cars that were using the compound for scrutineering for a Whariti Rd hill climb). Together we set off towards Makairo, noting no sign of bike passing in then gravel roads. Then, not far from Makairo, lot of sign. Okay, guess they came in a different way. (Photo by Bart).

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    Bart & five of six others were waiting at the entrance. He noted more riders were expected from Dannevegas.

    The group (when it finally assembled) consisted of: Me - Box’a’bits (R100GS); Bart (DR650); Waihou Thumper (Husky 610); DR Girl (Dr200); Nic (XT225); Chris (KTM 690); Hugh (DR650); GPS Man (KLR650); GSers (R1100GS); Clint 640 (KTM 640); Rosie (WR250R); Waipukbiker (KL250); Pomgolian; and a couple of others who I didn’t really get an opportunity to catch up with.

    Makairo Track is a disused road, which has reverted into single track. It runs through bush, & up along a ridge line, to an open summit, and then a descent into a quarry. It is infrequently maintained, & is now mainly used by hunters & mountain bike clubs. I don’t think that you could get a 4WD through it now, given its overgrown nature & steep drop offs on the right side of the track.

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    I grabbed a handful of stinging nettle at one point when I jumped off to help Nic. She graciously allowed me to photograph the moment.

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    Gerard cross rutted fairly early on, with inevitable consequences. Later he dropped a wheel off one bank, which we needed to lift back up. Gus beached both jugs on the downhill section in one of the ruts. It definitely proved a workout, & I was fairly tired by the end of the track. (Photo by Bart)

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    Bart took the group over Towai Range, & down to Little Manuhara Rd, another disused road, now likely used as a stock route. This starts promisingly with hard packed limestone, but deteriorates as it climbs into Macrocarpa trees (ruts & roots) & a bit of slick mud. It was my turn to cross rut in there – I landed hard on my back & was later surprised my camera (carried in my camelback) survived the impact.

    Lunch stop at Pongoroa, at the general store. I overheard several comments surprised at how few kms we had traveled compared to the felt work rate.

    After replenishing reserves, we headed down Coast Rd to Akitio. Bart had organized access across Akitio Station & also across Tautane Station. This was generally wide well formed tracks, paralleling the ocean.

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    There was one stream ford there, which had obviously seen some water thru it. The ford was concrete, but the stream had been up on one bank, creating a silty bog. No real issues once you were on the ford though, & no one took advantage of the number of cameras pointed at them to fall off. (Photo by Bart)

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    At the Tautane Station we had a moment with a station horse, who decided to play race the bikes. Clint attempted to overtake on the grass, only to find a culvert. Whilst he made the jump over that, he dumped the bike turning back onto the track.

    Bart decided that discretion was the better part of valor when the horse decided to run straight at him to get thru a gateway. I hope there wasn’t any issues with the station when they discovered their horse a few miles (and paddocks) away.

    About then we discovered 2 of our party were missing. Wade went back for them, but they had disappeared. It seems that when we made a right turn to go to Akitio station, they went straight ahead. I guess the lesson is to make sure tail end Charlie is fully aware of the route. Fortunately we caught Nic again at the Porangahau Hotel (she was probably just thirsty). Hugh eventually turned up after dark at Napier, having done a bigger tour than he’d anticipated....

    Bart had been concerned about a climb out of the Tautane Station. This had been pugged fairly recently, but dry, & was fun with reasonably good suspension.

    Having left the station we moved on to Blackhead, & rode the beach over the slip (which now had a track across it) to Pourerere. We were much later than expected, but fortunately the tide hadn’t come up too far. I really enjoyed this section on Gus. (Photos by Bart)

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    Followed Pourerere Rd back to Waipawa for gas, riding straight into the weather front which had been traveling along the hills. Still only light rain. At Waipawa a few decided to exit for Home. The balance went inland to Range Rd, then Argyll Rd, only to the turned back at Rauakwa Rd when we came across an accident (fatality). Back Te Onepu Rd to SH2, to Westshore Holiday Park, Napier to overnight.
  9. Mark_S

    Mark_S Fair Weather Faggot

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    looks like a real traffic jam in the middle of the Makiro

    so where are all the photos????

    excuses count for NOTHING
  10. Box'a'bits

    Box'a'bits In need of repair

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    Up earlyish Sunday to do some maintenance on Gus. Beautiful day.

    Left Clint & Rosie at the camp – they decided to leg it home.

    The return leg consisted of me, Bart, Wade, Chris, Waihou Thumper, Nic, & GSer.

    Breakfast at Meadowdale New World, just so that Bart could dump his gear on his mum.

    Over the Gentle Annie, all sealed now, but riding into wind & light drizzle. It got quite cool up there to. My riding there wasn’t the best then – just didn’t have my head I the right space.

    Turned off at Matawhero Station. Brilliant, flowing, open & damp gravel road (no dust). (1st Photo by Bart)

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    Lunch at Taihape at the Soul Food Café. Try their Steak Burger. Yummmy...

    We lost Nic & Chris there, as they went North.

    Then Toe Toe Rd at the bottom of the Mangaweka Deviation, Kawhatau Valley Rd, Auputa Rd, & through to Apiti, where we sat in the pub to wait for a rain cell to move across. We cleared out before 90 odd police & search & rescue people descended on us. By mutual consent, we decided to forgo Takapari Rd. It would have been miserable up there. Makoura Rd, Pohangina Rd West & on to Ashurst where the group fragmented again.

    GSer & I went around the back of Palmerston North, Then I headed for Wellington. Home 5.00 ish.

    Cool weekend Bart. Thanks for organizing it.

    950kms over the weekend

    Took the day off today to recover.
  11. Box'a'bits

    Box'a'bits In need of repair

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    Never work on your bike after attending a work function. Always allow sufficient time before an event to get all maintenance squared away. :brow This will prevent any messy & embarrassing oil leaks occuring during an event.

    Forgot to put the bolt between the airbox & gearbox in..:shog...resulting in what looked to be a massive oil leak at the back of the gearbox (actually not much oil, but it went a long way).

    The fork seal never did (seal), & pissed me off all the way round, even after the business card trick. I have a new one to install.

    The brake lever became noticeably grabby going over Gentle Annie & I ended up taking it out & cleaning it up in Taihape, with lube courtesy of the engine oil dip stick.

    Got home & washed Gus. While I was doing that I noticed a funny molding line on the spark plug cap. I checked it & it turned out that the cap must have taken a wack at some stage (I theorise at the Odlines Rd ride) & that is why it hasn't been coping with the wet too well (cutting out & running on one). Its the left side plug cap, so would be facing backwards, so maybe why it hasn't reacted to rain.

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    Nope, but I can't always see the indicators flashing (from behind) in the sunshine.

    I don't want to replace the indicators because that be expensive & complex given the BMW system of a switch for left, a switch for right, & and an indicator off switch.
  12. Padmei

    Padmei enamoured

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    Good writeup Nutso.:clap Looked like a good crowd & nice setting. It was absolutley pissing down here on Saturday so I was wondering if you guys were having fun.
    It is bloody annoying taking the time to take photos but worth it when you look back after a few years. Leaving the bolt out:roflI can imagine the mess in the airbox.
  13. Box'a'bits

    Box'a'bits In need of repair

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    Happiness is a dry set of fork legs. Won't be using All Balls Fork seals again. They are junk (at least for my application). Used two sets of 'All Balls' seals, & neither did their job. They held fine until the weight of the bike was down off the stand, i.e. I had everything back together.
    :becca

    Oh well, I guess I am well practiced at fork oil & seal changes now.

    Finally got a seal using the cheaper no name fork seals I'd taken out when I did the bushes.

    Next job is putting some resistors in the indicator wiring to stop the hyperflashes, then I'll take the bike back for the WoF re-inspection
  14. Box'a'bits

    Box'a'bits In need of repair

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    Let me start with a disclaimer & assertion. While I love figuring stuff out, I generally hate playing with wiring & playing with electrics, mostly because I have trouble finding out where the magic smoke leaks out. I can do it – but I prefer not to.

    Why Did I Do This:
    Some time ago I replaced the stock 21w indicators with KTM 10w ones. This was primarily for aesthetic reasons, but also because I thought the smaller & more flexible KTM units would be more durable (& because I got them at the right price).

    The replacement has caused an issue, because the flasher unit has detects lower current draw, & thinks that indicates a bulb is out, resulting in hyper flashes (the indicator flashing much more rapidly than it should).

    Until now I have put up with this, & have actually gone thru’ a couple of WoFs without this being presented as an issue. However this WoF check I was pulled on it. As a result I need to do something to remedy it.

    Resolving The Issue:
    There are generally a couple of ways to resolve this issue: 1. Get a new flasher unit that can accommodate the difference indicator draw; 2. Get an electronic flasher that isn’t sensitive to current draw; 3. Wire in resistors to increase current draw to approximate the current draw of the 21 w units. Here’s a link across to some else’s site, where they’ve looked at solutions to the problem.

    It was always going to be problematic & somewhat expensive to replace the stock BMW flasher unit because of the manner in which the switches work (left switch, right switch & cancel switch). The stock unit has about 8 wires running into it. Not an easy replacement, & expensive if possible.

    So I’ve chosen to go the ‘cheaper’ resistor pathway. The appropriate resistors are $2 ea at Jaycar. Rather than have a resistor per indicator, I’ve chosen to have one per side. The resistor ‘burns’ current as heat. I’ve chosen to hide the resistor in the headlight bucket. Realistically the indicators aren’t on for too long, & so I’m not too worried about airflow to dissipate that heat. You just wouldn't want to hold the resistors if you have run the indicators for more than a couple of minutes. I figure no worse that the H4 bulb though...

    The Theory:
    To figure the load difference, Google told me that Ohms law states V=IxR, or R=V/I
    V= voltage, I = current (measured on amps), R = resistance (measured on ohms).

    On Gus the voltage varies between 12.6v min to 14.2v max. (using an Enduralast alternator & regulator).

    The difference between the indicator load is (stock 21w x 2) – (KTM 10w x 2) = 22w.

    22w / 12.6v = 1.788618 amps (min). 22w / 14.2v = 1.549296 amps (max).

    12.6v / 1.789 a = 7.04 ohms resistance (min). 14.2v / 1.55 a = 9.16 ohms resistance (max).

    Parts:
    Given the flasher is off ½ the time, then a 10w resistor is said to be acceptable. This comes is a variety of resistance values, but I choose 2x 8.2 ohm resistor - one per side (the resistors available were 10 ohms, 8.2 ohms, or 6.7 ohms). I’ve made up a little sub loom to accommodate the resistors, running in parallel with the normal indicator circuit. I also took the opportunity to tidy up one connector block, by taking this into the headlight shell.

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    Tested & works well. Success!

    The Bloopers Reel
    The link for the Gixxers above shows 10 ohm resistors. Didn’t work. But running both resistors thru both indicators did. But interesting factoid. 2x 10 ohm resistors doesn’t double resistance. Does your head in. The difference was the resistance in the additional 10w bulb.

    Postscript 07/04/2012:
    Took Gus for a resit for the WoF. Passed. The initial test was at 210,495. The re-sit 2 weeks later was at 211,454. Must have been all that time on private land & road, Sir.

    Postscript 22/05/13:
    Had an accident 25/11/12, which turned Gus upside down & tore out the wiring on the left front indicator. Because I couldn't see that the left indicator was flashing, I rode home without that corrected. This overheated the resistor for the left side, melting the heatshrink, then because the resistor was close to the H4 bulb holder, melted that too. End result was nearly a fire. Fortunately the headlight relay fuse popped (it's also in the bucket) & the resistor burnt out before too much further damage occurred.

    I have since relocated the resistors at the rear of the bike, with the resistors epoxied inside a steel tube, clamped to the frame. That gives a better heatsink, & no opportunity to overheat any other component. It also protects the ceramic exterior of the resistors. Much cheaper than the set up you can buy from Trademe or Ebay.

    [​IMG]

    Interestingly I needed a 6.8 ohm resister to replace the burnt out 8.2ohm one. Obviously here is some variance within the ratings.

    I have also mounted LED indicator warning lights just under the speedo, so a burnt out bulb shouldn't allow the same thing to happen in the future.

    [​IMG]
  15. Padmei

    Padmei enamoured

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    Yes well as you my remember this electrician went thru many nites of non sleep working out the resistance for mine. parallel values, series values, distortion & harmonics, salami & feta - there was no end to it.
  16. advNZer?

    advNZer? Long timer

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    there obviously was...you talimg past tense
  17. Box'a'bits

    Box'a'bits In need of repair

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    Basically he gave up & threw the baby out with the bathwater. He went all KLR on us with his switchgear (because he had some), stripped a huge amount of now surplus wiring out, & used a much simpler flasher unit.
  18. Padmei

    Padmei enamoured

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    That pretty much sums it up. I never liked the BMW indicator switches either. I'm not great fan of the peripheral BMW wiring - pretty much overkill for such a basic bike.
    It's a similar story how things get changed on my bike. I ended up replacing the brake lever & master cylinder, throttle & starter switch etc cos the original master cylinder was weeping & the replacement piston etc that 'may' have fixed it was pretty expensive. Once again I used some KLR parts hanging around.
    I'm thinking of replacing one of the cylinders with a spare 650 barrel I have lying around. Just gotta get the grinder out to cut some cooling fins unless I can use a stock oil cooler as a radiator for it.
    It'll be a Schmidtenrock 1050

    Heyyyy i think I have a spare KLr side stand lying around - that may solve my missing LHS crash bar problem.:evil
  19. Box'a'bits

    Box'a'bits In need of repair

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    This morning I went across to Ocean Beach again with EddieB. I'll let the photos do the talking

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  20. Dino3310

    Dino3310 Been here awhile

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    Nice one mate, nice photos.
    Good to see EddieB back in the game:clap