Rear End refurb

Mr. Orange / Excellent pictures!!!! I rebuilt my front calipers this year, I swear I spent more time cleaning them than the actual dismantalling took. Used some special acid to anodize the insides of where the pistons go. Cleaned off all the tea stains from the pistons and I couldnt wait and ended up using the old seals. They are tough and cleaned up perfect with the aid of my finger nails. Even looked at em under a loop before re-using them. Satisfying job for sure, I got EBC rotors on the front and was never impressed with the bite, now...its just a one finger affair more or less. Nice modulation too, no more wooden feel. I liked the way you illustrated the back hub removal. Maybe when my viffer hits 100,000 I will do it too. Cheers

 

Kewel the way you used the drill to polish the allen heads. Your giving away all your trade secrets DUDE!!!. I did all my 1/4 d-zus fasteners along with my frankenstein bolts and the rest of em on a buffing wheel. They look like chrome now. Got a long term love affair with this bike, I swear its in better shape now cosmetically and mechanically than when I bought it 15 years ago with 4000 on the clock. Laterville

 

Very cool project. Nice write up and the pics are top notch.

Thank you!

 

OK, finally was able to get mine apart. The axle yoke was completely corroded and my bearing surfaces were rusty and corroded to the axle. I had to re-polish the axle and actually bought a used one on e-bay for $70. I should get that one today. I re-packed the bearings, polished the axle, scotch brighted the inner bearing bores and am ready to finally re-assemble. This is a great project. I think I will do this once a year. I would imagine that it is quick and easy as long as the parts are not rusty and corroded together. I guess this is the problem with buying an older bike (1997) with low mileage. I had no idea how long it had been sitting before I bought it, but it looks like it had been sitting a while. Almost done....thanks for this post and the pics. What a resource!!

 

Hi folks, been ages since I last posted. I put my blinkers on and finished the bike. I've been commuting on it the past few weeks and am incredibly happy with it.

Some more pics below:

Feeling horny?
While waiting for my air filter to arrive I distracted myself with little jobs such as cleaning up the horn.
before

old paint removed

repainted


My main stand arrived from a breakers (yellow marker pen is a give away) and needed a thorough sanding, followed by acid etch and hammerite smooth. I repainted the springs (I was bored!) with a copper esque paint.
before

after


I also wire brushed the exhaust system, rust treated and repainted it.


Unfortunately, I accidentally picked up a lower temperature range of heat paint than I thought I had, d'oh! Most of the system has kept its new look, but the headers burned it off after use. Will have to be re-done nearer winter with the proper stuff!


Unfortunately, in my determined mindset to get out on the bike, I didn't take the 'finished' photos!!

These are after a few weeks of use, so not as clean as it once was. Still, a galaxy apart from how it was when I got it.







After a few days use, I was disappointed with the walking speed response. I had changed the air filter, ran a fuel system cleaner, drained the carbs and changed the plugs for lovely new irridium plugs. It was only when I changed the fuel filter that the bike became smooth and confident at low speeds.

There was a clog in the old filter causing a coughing sensation at idle, but it disappeared higher in the rev range. A very simple fix. What caused the clog? I suspect sitting still for 3 years and old fuel turned into that nasty powdery sludge, but I'll keep my eye on it. My tank seems very clean inside (from what I can see anyway!).

I'm just happy I didn't have to strip the carbs!

Next on the to do list: new tyres!



Mysta, no bearings needed replacing. I contemplating replacing them anyway, but the large rear bearing is actually pretty pricey and the budget is tight. All were ok so only needed inspection and re-greasing.

ridervfr, i hear you on how long the cleaning can take. Very interested in the special acid you used, got any info?