The rehabilitation of Sir Gustave Sebastian

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

  1. Box'a'bits

    Box'a'bits In need of repair Supporter

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    When last we left our intrepid hero... I was about to drop the gearbox. Now I may have been a little premature in cursing Rob. Certainly the oil did have a little water in it, and it was red, but in the cold light of the next day it was thicker than I initially thought.

    Gearbox came out fine, disconnected the clutch cable & arm, disconnected the gearchange linkage, dropped the two bolts at the bottom side, slid it backwards, & put it aside for a later clean up. While it was out replaced the neautral switch, which is fairly inaccessible when the gearbox is in place (sits between the engine sump & the bottom of the gearbox). I suspect that this was not working because it sits at the lower point of the g/box, & was water contaminated.

    The clutch housing was dirty but oil free (good). (By the way the photo is after cleaning & reassembly). The splines looked good, & not dry. Prior to disassembly I found TDC, & marked the pressure plate, clutch etc so that it could go back together as a balanced assembly. Un-did the six allen headed bolts holding the clutch together. Surprisingly didn't need any 'clutch let down tool'. If this was needed I was going to use a longer bolt with a nut screwed part way on, to let the tension off. The outer pressure plate looks scorched (?) - maybe a bit of slipping in the recent past?. Ignore the pink nail polish which has ended up on the plate :smooch
    [​IMG][​IMG]

    The clutch plate is wearing in a taper to the outside (5.75mm inner, 5.25mm outer) & it is starting to break up around the rivets. Wear limits are quoted at a number of different place at at number of different sizes, so difficult to tell if this is totally shot, but it will be replaced in the near future because of the taper & the breakup.
    [​IMG][​IMG]

    Reinstalled the clutch, given I need the bike this weekend. I have a clutch alignment tool, which makes this easy. Basically this fits through the clutch splines & holds everything in place while you tighten the allen headed bolts.

    While gearbox was out, I took the opportunity to drive out the rear engine mount (supported the engine with a jack to take the pressure off this), clean the bolt up, lube it & push this back in. These have a habit of corroding in place. Also took out the alloy spacer which sits under the gearbox, & did the same.

    Cleaned up & lubed the gearbox change linkages. One o'ring on the linkage needs replacement (holds the grease inside the pivot bushing).
    [​IMG]

    Cleaned up the clutch pivot arm (note bearing no for future reference, as the inner race is pitted).
    [​IMG][​IMG]

    I also opted to do an engine oil & filter change. The oil was fairly black. Given all the recent discussion re the $2k o'ring, I check the canister depth. This was 3.5mm, so using Anton Largiers calculation, I used a shim when I buttoned everthing back together (the bike didn't have one, but I've a few spares here & there). Shim in 1st, then the white o'ring, no gasket. As I noted earlier I have ridden airheads 20 some odd years & this is the 1st time I've taken any notice of this.

    Pinched the magnetic drain plug from the RS for the gearbox. This is so I can keep an eye out for damage. Replaced the oil with Castrol 80/90. Reinstalled the gearbox. Note to self, need to get another magnetic drainplug to replace the RS's.

    I also swiped the oil cooler of the RS to measure this against the GS, in the hope that I could use this to relocate the oil cooler from the crashbar. Unfortunately noted that: 1. In the Touratech kit the oil cooler sits one brace up from the RS, and; 2. As a consequence, the oil lines are too short. Also note that you cannot just bring the cooler down to the bottom brace, because the mudguard won't allow this, & if you use the GS frame mounted fairing then the cooler will foul the kangaroo bars. The top brace has a centre tube going back into the main frame that would mean the cooler wouldn't be centred. Might has to rethink this.

    Stretched a new gearbox output / driveshaft boot over the swingarm before reinstalling the swingarm. Before reinstalling I had cleaned up the swingarm pivots, & bearings. Then reinstalled the swingarm, made sure that the gap between frame & swingarm was even (circa 7mm), & torqued the pivots up to spec. The box spanner is useful for allowing the lock nut to be tightened initially, while the allen key holds the pivot. Once this is tight, then you can torque the nut.
    [​IMG]

    Tightened the 4 drive shaft bolts with the 12 point 10mm /12 mm BMW spanner & a bit of leverage. I loctited but didn't replace given I'll be back in there in the next few weeks.

    By supported the swingarm horizontally, the driveshaft boot fit on 'more easily'.
    [​IMG]

    Decided to embark on installing the right side touratech pannier frame, to finish the weekends work off. Both sides needed a little massaging to fit properly. Initially I was a little disappointed with them. The KTM racks were mostly tubing. The BMW ones use flat straps to connect to the footpegs & bottom of the sub frame. However now they are installed I can see better how these will work, & I've changed my mind (more positive). I've already got aluminium boxes from the KTM.
    [​IMG] [​IMG]

    The Postie brought more presents today (Monday 30th Aug). Tonight's jobs was filing knurls off some new bars.
    [​IMG]

    BMW bars are slight smaller than most other manufacturers. Their clutch & brake perches can be a bit brittle if you attempt to spread them to make them fit. I've pretty much got it done now, but it's been a frustrating night......

    Most of the big bits are back in place. A few issues to resolve yet. But I should be good for Saturday.

    Alex, I'm already there....:rofl

    Steve
    #21
    murin likes this.
  2. Kokopelli

    Kokopelli Yeah, right!

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    You can have that clutch reconditioned. Seems to work well and is relatively cheap.
    #22
  3. Padmei

    Padmei enamoured

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    Great progress Steve. I am looking on with interest & appreciating all the little details & tips for when I come to pull mine out for a looksie.
    #23
  4. Oaters

    Oaters Old - not bold - moto riding addict

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    Excellent thread Steve - I'm impressed - onya!
    #24
  5. Box'a'bits

    Box'a'bits In need of repair Supporter

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    Good to know Alex. Did you get that done at a Brake & Clutch place or was there a specialist? I've an oil fouled one lying around here from the R65. Never sure if those places just replace with new parts or make their own...

    Knew that I was right never to throw used bike bits away!! :clap

    Also have you ever had the rear brakes shoes re-done? Over on Advrider I read that the stock shoes are way too hard, & that is the actual issue re the poor rear brake. It might be worth an experiment.
    Padmei & Aslan, good to have feedback. Makes a worthwhile boost to recording these details...:D
    #25
  6. Mark_S

    Mark_S Fair Weather Faggot

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    stop typing and get working

    you are my excuse to get away from some big family gatherings this weekend
    #26
  7. Padmei

    Padmei enamoured

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    :rofl :rofl :rofl :rofl :rofl
    #27
  8. Kokopelli

    Kokopelli Yeah, right!

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    http://www.autoclutch.co.nz/

    These guys did mine. I am sure they can do drum brakes as well.

    If you do end up using someone like them, you'll need to punch mark the components, as they will bead blast the parts as well. My marks were gone, not that it made a difference.

    $170

    [​IMG]

    [​IMG]

    However, this clutch is not currently in the bike. I had thought there was a problem with it and swapped it out. Turned out that the problem was elsewhere, but couldn't be bothered to swap it back in again.
    #28
  9. Mark_S

    Mark_S Fair Weather Faggot

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    so what's happening????

    have you got that piece of Bavarian refuse ready to ride or what?









    BTW - if its pissing down tomorrow morning I'm staying in bed
    #29
  10. Box'a'bits

    Box'a'bits In need of repair Supporter

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    Haven't fired it up yet. Still a bit of wiring to do to keep my pinkies warm. Quietly confident (or panicking dependent on whether you're talking to me or Mandy).

    Will knock off work early so that I can sort that. Nothing like leaving things to the last minute. :rofl :rofl

    Pussy. I'll be round to roust you out.. What' your address again? :evil
    #30
  11. Mark_S

    Mark_S Fair Weather Faggot

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    well?

    Mr tour leader whats happening?

    the sun i shining
    my gears all packed
    the klr's all prepped

    I'll be at Waikanae at 8am
    Tony (DR650) will probably be there to (day tripping)

    if for any reason you don't show by about 20 past 8 I/we will head up to Shannon for a coffee

    if you aint comin can you txt me on 0274499115
    #31
  12. Box'a'bits

    Box'a'bits In need of repair Supporter

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    It was my threat to come round & do you mischief that got you going wasn't it....:D

    I'm up & running. See you at 8.00am. Still haven't decided on a route. I'll leave that to concensus (& how well Gus is running).

    Cheer, Steve
    #32
  13. advNZer?

    advNZer? Long timer

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    great stuff you guys are getting me all fired up about the PD again.Riding it around the last couple of days has me seriously considering upgrading the forks.There is an ohlins shock already sitting in new plymouth for me but things like achilles tendons and broken hall sensors have got in the way.
    #33
  14. Padmei

    Padmei enamoured

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    Put the front wheel on Schmidt today & rode down the drivewayto get the mail & back. Very rattly & noisy so I spose that's good:D

    It will be good to have a front brake tho. After riding Gonzo today I wonder if the BM will be up to standard performance wise in comparison.

    I've been pondering if there's an easy way to put a disc on the back- I know Phils done one.
    #34
  15. advNZer?

    advNZer? Long timer

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    not an easy way,but it would help to pull it aprt and make sure that every thing is as it should be.My back brake is hopeless too
    #35
  16. Box'a'bits

    Box'a'bits In need of repair Supporter

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    Chicken & the egg. Assuming I get the brake caliper, then you can borrow mine. Assuming you get your engineer friend going...:wink:

    Just back from the Kiwi. About 1000kms for the weekend. Bloody good times. But needs brakes...:lol3
    #36
  17. Padmei

    Padmei enamoured

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    OK I'll get this adaptor underway but not sure how many to make. You mentioned you may want to fund making 10 & reselling them ? Did you want to advertise first on aussie thread & see if any takers? At the moment I have 5 takers costing about $60 each for 5 whereas 10 would cost $30 each.
    What do you think?
    #37
  18. Box'a'bits

    Box'a'bits In need of repair Supporter

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    Go with five. Flick me a PM & I'll dump some cash in your a/c. You can return this once the five are gone. Cheers, Steve
    #38
  19. Box'a'bits

    Box'a'bits In need of repair Supporter

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    COLD KIWI 2010:
    In the interests of saving time for you skim readers, & dealing to any tension you might have felt, Gus was up & running for the Cold Kiwi weekend.

    He successfully managed to run for the round trip of 873kms.

    [​IMG]

    But I didn't get him up & running until about 10.30pm Friday night, & given the conditions (absolutely bucketing down) I didn't get a test run in. Part of the delay was wiring in an essential piece of equipment - the heated grips.

    Made it to the 8.00am meeting place at 8.20am - I needed to reinflate tyres (they were sitting at 20psi), but discovered the local air lines wouldn't accomodate the BMW rear wheel / valve stem.

    Carbs also need a good strip & set up. The idle mixture was set way high, & the carbs wouldn't balance. A strip is in order. They'd run on occassionally, which was 'interesting' in some corners.

    Initial ride impressions were of a very torquey motor, faster than the KTM, stable on seal or gravel (the shock still has some damping), no brakes to speak of (work with a full hand squeeze - not 2 fingers). The seat height's a lot lower than the KTM. I kept catching myself trying to do the balance / scramble I had perfected on the KTM, but no longer need. Whilst the bars seem quite high they are perfect when standing. The pegs / seat relationship is a little cramped & I need to build the seat up.

    The alloy boxes just work a heap better on the BMW than they ever did on the KTM. On the KTM they were 950mm wide (air brakes). On the BMW 800 wide. The KTM felt like they were too far back (to accomodate a pillon that was never going to be there).

    The clutch slipped once, out on the gravel.


    [​IMG]

    Rode with GuzziTony on his highly modified R80G/S, & Mark_S on his wanna-be KLR. Took a route via Ashurst, Pohangina, Ridge Rd, Apiti, Mangaweka, then Taihape for lunch. After lunch Mark_S left bound for Napier via the Gentle Annie, GuzziTony & I went to the Kiwi site, were I met up with EddieB, & an old friend Paul Roberts. Paul's had a R100GSPD (Miami Vice colours) from new.

    The Kiwi was a lot of fun, caught up with a number of friends I don't see for 12 mths. They'd had snow Friday (2cm), but it was largely gone before we got there.

    [​IMG][​IMG]

    Sunday rode over the Gentle Annie with Paul, met Mark_S at Omahu, & rode Valley Rd / Argyll Rd across to Waipawa for coffee. In amongst that had minor issue with the speedo drive & battery strap, soon resolved.

    [​IMG]

    Then rode Blackhead Beach, Porongahau, Wimbledon, & Weber. The wind after Porongahau was threatening to blow us off the bikes, so I wasn't particularly enjoying the ride. Mark_S convinced me to continue through to Pongaroa, where things improved but rain threatened. Then Pahiatua, PNth, Otaki, & Home at 6.30pm.

    [​IMG]

    The bike appears to be getting about 15 km/litre (35mpg US), which I find a bit thirsty, but it was being pushed at times.

    Surprisingly good grip from the munted IRC 110 GP whatevers. But they howl somthing aweful. :lol3

    The sump gasket is leaking (it was weeping before the trip), but I was going to drop that anyway, so an easy repair. The neutral switch doesn't appear to be making good contact - the light is very dim. Either crap in the switch again, or the external wiring connections need uncorroding. When riding I can feel a regular ticking coming from the bike. Haven't diagnosed fully yet. Suspect (but hopeful it is not) gearbox or final drive.

    Found the headlight surprisingly poor. I expected this to be much better, coming from the KTM. I need to investigate why that might be (aside from not being set up right). The mechanism which allow adjustment appears broken & the light has a lot of movement in it. Until I know if the fairing is going to stay, I won't be repairing that however..

    I've won an auction on a 4 pot Tokico caliper off an RGV 250 tonight. So that's next on the list of upgrades...
    #39
  20. Padmei

    Padmei enamoured

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    Good stuff Steve. They're interesting to ride after more modern bikes I think.
    I have to say the Red is a revolting colour (I can say that cos mine is too:D ) - even worse than the Ghey gravel rash colours, so a paint job may be sooner rather than later for me. mark could do with one too - I've still got somewhote rattlecans.

    That G/S looks interesting. I love the old Marlboro paint jobs. Any more details about that bike? It loks like a cool pipe on it.

    BTW are the pics from the cold kiwi fairly indicative of what you do there- stand around fires & drink piss? :freaky I've never been to a rally yet...
    #40