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Discussion in 'Some Assembly Required' started by G 981, Dec 3, 2018.
Just me being a nitpicker, you have to look hard to imagine a fault with your bikes.
I was thinking more along the line of these thin Nylon washers 0.5mm thickness various sizes
My bikes are far from neat or standard, not including your Goldy, I forget your hotties name Grant. I like to use 20mm x 3mm thick plumbers fibre washers and a big flat stainless washer under any cup type fairing washers. Or I did till Plumbers stopped using fibre tap washers. That's not going to work on the one in the pic though. It protects the paint and spreads the load on Plastic or Fibreglass. Just seen too many timber screws pull through stuff over the years.
The load is spread across the really wide head on these screws.
I also use a penny washer on the other side for the nut to grip on to.
Anyway, today was a case of 2 steps forward...
Started installing the Redax ignition/alternator upgrade.
Fit the Woodruff key to the crank
2019-10-06 10.12.07 by Grant Duguid, on Flickr
Thread the wiring through the cases
2019-10-06 10.13.34 by Grant Duguid, on Flickr
2019-10-06 10.22.50 by Grant Duguid, on Flickr
2019-10-06 10.24.50 by Grant Duguid, on Flickr
Adaptor for stator
2019-10-06 10.20.56 by Grant Duguid, on Flickr
2019-10-06 10.21.18 by Grant Duguid, on Flickr
2019-10-06 10.42.10-1 by Grant Duguid, on Flickr
In order for the wires to thread through the cases under the starter motor the connector block is fitted after it's threaded through.
7 pins to fit into 2 connector blocks. 6 went in fine, 7th wouldn't click into place and when I persuaded it the bloody thing broke.
So, on to Ebay to buy a Deutsch kit...
I just felt like I was pissing against the wind today so I stopped after this and now have a beer in my hand.
Not a lot done today.
The special connector to the headlamp turned up this afternoon.
2019-10-07 14.45.12 by Grant Duguid, on Flickr
And I plumbed in the fuel hoses.
2019-10-07 14.45.34 by Grant Duguid, on Flickr
Hopefully the Deutsch pins and crimp tool will arrive before the end of the week to allow me to complete ignition installation.
Starting to make progress now.
Still waiting on the new Deutsch pins to arrive so I can fix the broken wire on the ignition wiring.
Fitted steering lock
2019-10-08 13.43.31 by Grant Duguid, on Flickr
Fitted plastic knob to seat release catch
2019-10-08 12.44.30 by Grant Duguid, on Flickr
2019-10-08 13.36.35 by Grant Duguid, on Flickr
Fitted cams and adjusted shim gaps
2019-10-08 10.09.01 by Grant Duguid, on Flickr
2019-10-08 13.16.29 by Grant Duguid, on Flickr
Filled the engine with oil
2019-10-08 14.02.30 by Grant Duguid, on Flickr
2019-10-08 13.50.42 by Grant Duguid, on Flickr
Tomorrow I'll bleed the brakes and connect the battery to test electrical connections.
Once the pins arrive (scheduled tomorrow) I'll finish off ignition wiring and get her fired up.
Are those connectors originally used?
BTW. Love the thread, read it every day :) Still dreaming of a RGS1000, but it's still out of reach
On early ones (which also had CDI ignition) yes.
Later ones (with BTZ ignition) moved to more modern multi-pin connector blocks.
The RGS is lower priced than earlier triples at the moment, a good time to buy.
I'm used to japanese bikes, so used to seeing multi-pin connector blocks, hence the question.
I'm still saving for a house (with garage) and only started working fairly recently, so the budget for bikes is quite tight. Might have to think about selling bikes to fund such a purchase (but the difficult question is then, which bike ).
The multi pin electrics were from 79 onwards.
I have an very nice SFC 1000 available, last model year, 1989......
Got the network manager on the case, she cleared the cache. All right now. According to t'internet, Flicker is a bit flaky atm. Some windows or firefox incompatibility.
As I log off after every session, and all browsers are set to not remember history and clear the cache, I didn't think to do this straight away.
Not much today.
Had to go to the plater to get some zinc stuff back, some of which went on 007.
Connected the throttle cable.
Started bleeding the brakes but had some issues so I'll have to investigate tomorrow. Front m/c not working properly despite new seal/piston and ultrasonic cleaned. Another seal/piston kit ordered.
Rear brake is always an SOB to bleed as the hose runs much higher than m/c or caliper so I'll remove completely and bleed it on the bench, then re-fit.
Deutsch pins never turned up so still got that to do.
The guzzi has the well known linked brakes - which I grew to like. When I replaced the "rear" brake line to the front calliper it was an absolute sod to bleed.
In the end I got a gunson Ezi-bleed. Did the job in 5 minutes.
The rear master cylinder was a size not provided. I mackled up a spare I had.
Functionally they are the same as the auto brake bleeder I used on the line as an apprentice many years ago.
I have also used to on the car when the ABS was being awkward.
I use a Mityvac but there is a problem with the m/c so even the Mityvac failed.
I'm not a fan of autobleeders that pressurise the reservoir. I have had the seal in the cap fail and spray brake fluid everywhere. The Mityvac sucks the fluid through via the bleed nipple.
I can’t help but think that’s also above budget
Those later SFC’s are also a bit cheaper than the earlier ones?
Stronger motor and upgraded brakes and suspension vs the RGS. Prices are quite strong.
Bled the rear brake but had to do it on the bench. It can be a real S.O.B., and it was so I removed the whole system to get it done.
Issues with front brake, waiting on a second new seal/piston kit to arrive.
Deutsch pins arrived this afternoon so I'll sort out the ignition wiring tomorrow.
While waiting on some parts in the ultrasonic bath I started messing around with one of my own projects.
I sourced a fibreglass copy of the RGS fairing minus filler flap and headlamp holes.
I plan to fit a round headlamp, just because I can.
This will mean modifying the fairing subframe to accept the headlamp and I will have to faff around with the instrument mounting to fit the hole available in the inner fairing.
Mucho trabajo, but that's the way I like it.
Why be samey?
2019-10-10 10.56.05 by Grant Duguid, on Flickr
2019-10-10 11.04.20 by Grant Duguid, on Flickr
2019-10-10 11.07.40 by Grant Duguid, on Flickr
2019-10-10 12.57.07 by Grant Duguid, on Flickr
2019-10-10 13.33.05 by Grant Duguid, on Flickr
2019-10-10 13.34.00 by Grant Duguid, on Flickr
2019-10-10 13.38.40 by Grant Duguid, on Flickr
Moving to the end game now with 007.
Fitted the Deutsch pins and finished off connections for the ignition.
Fitted the ignition pick up/rotor/stator and alternator cover.
Connected battery and test operated all electrics, all working perfectly.
Engine turns over.
Bought a gallon of fuel for test start tomorrow.
Battery on charge.
Still waiting on the front brake m/c seal/piston kit to arrive to complete the brakes and then it will be finished.
That parcel should be here Monday hopefully.
2019-10-11 10.22.12-1 by Grant Duguid, on Flickr
2019-10-11 10.23.29 by Grant Duguid, on Flickr
2019-10-11 11.22.14 by Grant Duguid, on Flickr
2019-10-11 11.23.20 by Grant Duguid, on Flickr
2019-10-11 11.25.24 by Grant Duguid, on Flickr
2019-10-11 11.25.15 by Grant Duguid, on Flickr
Then I faffed about a bit more with my own project.
Test fitted a headlamp and checked how much more finessing I need to do to the fairing.
I will need to cut/weld the fairing bracket to fit the round headlamp shell to the rectangular one built into the bracket.
I'm liking the round headlamp vs the standard rectangular one.
2019-10-11 09.42.28 by Grant Duguid, on Flickr
2019-10-11 09.46.55 by Grant Duguid, on Flickr
2019-10-11 10.48.19 by Grant Duguid, on Flickr
I'm still in awe of your skills G 981. Thanks for all the updates.