The rehabilitation of Sir Gustave Sabastian (‘Gus’)

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

  1. Box'a'bits

    Box'a'bits In need of repair

    Joined:
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    Back to work Mon 18th. I’ve tried to ease into it, but that’s not really the way things work there, so I’m probably adding to the backlog. Customers seem pleased I’m back though, which is gratifying.

    My admin person has been away for the last 2 days with (ironically) a bad back.

    I’d given up the Panadol & Ibuprofen Saturday, but needed to hook back into it Monday after work, & Tuesday & Wednesday lunch time. None today though.

    Had an appointment with the Orthopedic Surgeon Wed afternoon. He seems pleased with progress, & has said I should start to wean myself out of the back brace. That’s even earlier than was anticipated. But he did give me another 3 months supply of Ibuprofen. His student was cute too…

    Mandy seemed surprised that I didn’t ask when I could get back on the bike – but I’ll know when that’s feasible. She also sought his support on the hypothesis that folding washing was good physiotherapy – NOT…
  2. igormortis

    igormortis Cafe Reise

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    Hey, what have you got on the back of Gus at the moment - E09? I need to measure some clearances.
  3. Box'a'bits

    Box'a'bits In need of repair

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    Yes, albeit only about 4.0 mm tread left. Zoom round anytime (but be aware I am back at work now). :D
  4. Box'a'bits

    Box'a'bits In need of repair

    Joined:
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    Been a while since last posting as I have been waiting for my back to come good. At this stage I am still not able to ride, but have started on some areas of maintenance / repair, where limited bending is needed.

    Valeo repair:
    On the last MAD ride I did with Bart, the starter motor field housing lost its magnets. At the time I replaced the starter motor with the heavier Bosch unit from the RS. But the Valeo is lighter & more efficient, spins the motor faster, & doesn't draw as many Amps, so I have been keen to get that repaired. Part of the advantage of the Valeo is in the planentary gearing it uses, which is not available in the Bosch.

    I took the motor field housing off the starter (three bolts through the gear housing) & disconnected the heavy wiring from the solenoid.

    At least one of the magnets was clearly broken away from the motor field housing.

    At the end of the housing, I removed the 2 nuts to allow removal of the cover over the brush plate.

    Pry up the springs to allow the brushes to be removed.

    [​IMG]

    The starter motor armature coil in held in the brush plate by an e-clip behind a bush cover. The bush housing is just a press fit over the armature end. I removed by prying this up.

    [​IMG]

    The armature & magnets just fell out then. Surprise, surprise, all of the magnets have lost their epoxy bond to the outside of the housing, so it wasn’t just the one that let go. This is fortunate in a way in that the armature doesn’t appear damaged.

    [​IMG]

    The armature has a couple of divots in them. This is stock, not damage like I first thought.

    [​IMG] [​IMG]

    There is a little damage on the armature side of the brush holder. I don't think this is a deal breaker.

    [​IMG]

    I am waiting for the new housing & magnets from Euro MotoElectrics, for USD35. The housing + armature + brushes + holder is USD $115, & a new valeo starter motor is USD198 (on sale). Then there is shipping costs (about USD30 for the housing).

    Other:
    I'll update this post as a couple of other items I am working on progress.
  5. Voltaire

    Voltaire Titanium and Ceramic Hipster

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    I bought a Valeo off them a couple of years back, they also did a 'cheap' one for $99 US from memory. Turned out they could post two for same price so bought a good one and a cheep one.
    The genuine one I think is made in Poland, the other elsewhere....oddly the knock off one seems better made, its in the race bike.
    They use the same Valeo planetary one in my VW van, I had a go at fixing it once but gave up.... new one was $600. :eek1
    I do like things you can take to bits and repair, although life would be less complicated if I didn't.
  6. harrysmith1

    harrysmith1 n00b

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    This seems to be a quite tedious task with numerous windings. I done it with copper windings but something went wrong with rotations. What are advantages over using aluminum over copper?
  7. Box'a'bits

    Box'a'bits In need of repair

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    Absolutely no idea. I'm just trying to fix what has already broken. The armature appears fine. Its the housing & magnets that I am replacing.
  8. Kokopelli

    Kokopelli Yeah, right!

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    When my Valeo went belly-up, I had it reconditioned. The second time it caused problems I went and bought a Nippon Denso. Hopefully, that was a long term fix. I am all for repairing stuff, but sometimes there is wear on other components and you end up with an imbalance in the system, this in turn will accelerate wear. However, the decision is always made based on current finances and/or my ability to hide new stuff.
  9. Steve in NZ

    Steve in NZ scared/cheap

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    our cousin to the west seems to have quite a few bits that may help. I see he is also on the Facebook airheads page. John Olive so Dave Hunn has pointed out to me.

    got my visionxwholsale.com solstice 10 watt lights fitted with some MAP mounting brackets. know I can go out at night and see way down the road unlike the standard GS light which is just pathetic

    got the complete kit (2 lights wiring and switch with relay) landed for $312. NZ $ is even better against US $ now. free shipping. there is a way to also get 10% off price as well.
  10. Padmei

    Padmei enamoured

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    I keep walkingby the shimming plate in the workshop. I will send it back as soon as I can find a way to secure the choccy fish I owe you onto it without upseting the sniffer dog...

    Hey maybe I should put some drugs in there to fool it - Brilliant!!
  11. Eddieb

    Eddieb www.AdventureRidingNZ.co.nz

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    Hows the rider doing, healing?
  12. Box'a'bits

    Box'a'bits In need of repair

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    That's 2 choccie fish...still waiting on the one from your competition...Anytime is fine. I'm not in a hurry.
    Appointment with the Orthopaedic guy wed. Not to complain, but it feels like I'm going backwards at present...Must be the weather.

    [​IMG]

    Met Robert today with his mighty fine Bumblebee R100GS PD. He's had it from new. Very very nice. Wellington based. Slightly crappy cell phone picture. Need to get out & ride with him & his friend some time (probably next summer). WP shock, full bashplates, 320 disc & adapter, LED lights, barkbusters, round rocker covers, frame was stripped & powder coated a few years ago

    Valer Starter rebuild:
    Slight delay on that. My computer hates their web shop payment, because it thinks their ssl cert is dodgy. Might transact over the ph if I can get hold of them (tried a few time now).
  13. advNZer?

    advNZer? Long timer

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    ddint know there were bumblebee PDs...nice
  14. Mark_S

    Mark_S Fair Weather Faggot

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    so what did the quack say?
  15. Box'a'bits

    Box'a'bits In need of repair

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    Discharged from Orthopaedics. The fracture has healed. However the back will never be as good as it was because of the shape of the vertebrae, i.e. the fractures heal, but the shape of the end result (wedge) doesn't change.

    I have been referred me to a physiotherapist to strengthen the back. 1st visit saturday

    Apparently I can start riding again on the 4th of July (6 mths on from the injury).

    I have started to do a few projects on the bike in anticipation of riding, including rebuilding the Valeo starter, & getting the gearbox repaired.
  16. Eddieb

    Eddieb www.AdventureRidingNZ.co.nz

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    Yay! mostly anyway.
  17. Box'a'bits

    Box'a'bits In need of repair

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    NEAR MISS ELECTRICAL FIRE:
    During inspection post crash I noted that the left front indicator wasn't working, & that the left rear was hyper flashing. Also the headlight low beam wasn't going. After opening the headlight shell, I saw that:

    • The H4 bulb had blown low beam;
    • The H4 plug was melted;
    • The left front indicator had pulled the wiring out;
    • The insulation around the resisters was scorched & melted

    I've now replaced the fuse for low beam (fused relay in the h/l shell), replaced the melted H4 headlight plug, & determined that the resister for the left indicators is dead.

    I think what happened is that during the crash the front left indicator wiring was pulled out of the connectors, & then the left rear was going flat out for a while riding home, & I didn't see this. This eventually over heated the resister, & caused the damage. I will need to rewire with the resisters outside the headlight shell. I'll probably get the nifty alloy shelled ones. I'll also get some LEDs mounted somewhere so I can see when the indicators are supposed to be flashing.

    STARTER:
    The brush holder, new brushes, & Oilhead magnet field housing portion of the starter re-build kit arrived Wed - six days after ordering. But the airhead (clockwise rotation) field magnet housing is still in transit.

    The replacement Oilhead field housing (counter clockwise rotation) I mistakenly ordered is now on Trade Me. If you want to rebuild the Valeo on your Oilhead, have I got a deal for you...The housing is the improved one, which has the magnets held in with clips, as well being glued in.

    The rebuild goal is to refit the Valeo to Gus, & then reclaim the Bosch for the RS.

    NEW EXHAUST SYSTEM:
    I was never happy with the fit of the Keihan 2 into 2 exhaust.

    Gus is in at Cycleworks getting a new exhaust 'Y' mid pipe made up, which will allow me to link the Keihan 38mm headers to the SV1000 pipe, so that I get back to a 2 into 1 system. This will have a side benefit of allowing me to refit the centre stand.

    VALVES:
    Shortly after I get Gus back, he's due for some head work at Headmasters, in order to fit new valve guides, valves, & possibly seats. Smoking is so anti-social don't you know.

    TOOLS
    I have also ordered some Cycleworks Tools:
    • To allow me to remove the gearbox output shaft nut & coupling, so that I can get the gearbox drain plug thread repaired. This will eventually allow me to refit the original gearbox & clutch pack, & fit the current heavy flywheel gearbox & clutch back on the RS, &
    • To allow me to replace the main seal on the RS.

    RIDER UPDATE:
    I've been referred to Physio, but have realised that doing strengthening exercises is rather boring, & doesn't get stuff done here. So with this in mind, I have mowed the lawns & trimmed some hedges for the 1st time since late Nov. And surprisingly the back has been good. So...
  18. Padmei

    Padmei enamoured

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    Good work on the bike - keep up with pics.

    Don't get carried away with that back of your bro - take your time.
  19. Rosie!

    Rosie! Little MissAdventure

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    Rotorua, NZ
    Do those exercises:ddog
    Strengthening everything up properly will make the rehab process a lot easier. Which means you get back on the bike faster :evil
  20. Mark_S

    Mark_S Fair Weather Faggot

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    So... what?

    are you implying that you might be ready to sneak out for a ride soonish?

    I have another couple of weekends work on the new klr and then I'll be ready for something like a wairarapa loop or some such

    do your ekersizes you nong - I don't stop to help riders who snap in the middle....