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The Old Charger

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arlurt View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 20 Mar 2019 at 21:22
Thanks everyone, that makes sense, the clutch is a bit heavy by modern standards.  I'll give it a go as is and see how I get on, maybe I need to get some grip exercisers for when I'm sat in front of the telly?  Wink  Or riding the bike and using the clutch to exercise my left hand might work!

Other job tonight was routing cables for the starter solenoid and battery.



They're in, but I'm not happy with the routing to the starter solenoid.  I'll have another look tomorrow, it might be better to route the cables past the solenoid and come back at it from the other direction. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 426hemi Quote  Post ReplyReply Direct Link To This Post Posted: 20 Mar 2019 at 22:35
The pipe looks like a drain pipe off the bottom of the tank.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 07:25
Thanks 426hemi, I'll try to have a look at the underside of the tank and see if I can spot where it's come from.  It's been suggested that it's the overflow/water drain from the petrol tank filler neck, that they block up, and then rot off as mine appears to have done.
 
 
The area of the tank around the filler is a bit mucky, as though water has been stood there, and I guess that if the drain is blocked, and there's rain water around the filler neck, then that water will drop in to the tank when you open the filler cap.  So even if I don't re-attach the blue plastic drain pipe, I must check that the drain from the filler neck is clear.  Don't want water in the tank...
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 426hemi Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 07:42
I used a piece of welding wire and gently fed it down the breather pipes till it came out the other end.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 08:13
Sounds a good plan, I've got some MIG wire, useful stuff.
 
I'm also wondering if some loops of wire and a cable tie or two might help me change the shape of the Airbox Boot intakes from Oval to round... Smile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevex Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 12:42
Recommended that you do reconnect the drain pipe. A common fault is for the drain pipe that goes through the tank to rupture, allowing fuel to leak through the drain. Better it goes to ground rather than over your bike.
People say I don't know Jack Sh1t; but I do, he lives next door.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 13:41
Good point Stevex.  I guess the drain on the underside of the tank comes out somewhere near the exhaust header on the rear cylinder.  What could possible go wrong...?
 
Thinking about my sticky steering damper, caused by "dry" seals.  Can I just "wet" the seals again by injecting a little fork oil between the damper shaft and the seal?
 
I've made a small tool over lunch to un-do the brass seal retaining rings at each end.  The plan is to hold the steering damper in the vice with one end up.  Unscrew the brass seal retaining ring and put enough fork oil in the end of the damper to cover the seal so it can't draw in any air.  Then wiggle the shaft or tease the gap between the seal and the shaft with a needle to allow some of the oil in.  Put the seal retainer back in and then work the damper back and forth a few times.
 
Yeah, I know I'm a cheapskate. Big smile 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wigginsjp Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 17:29
The steering dampers do go off with age. 
They stick and wander if bad enough. Either remove or if you still want it, I had one rebuilt at MCT for £100 

Top post I'm really enjoying seeing your work. Plus I imagine Falco airboxes may evoke the next must have mod 😁
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wigginsjp Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 17:34
Also ref the tank and swelling. 

Yes they can do and do as described by also check your clip ons aren't bent. Sounds silly but numerous gen1's I've worked on have slightly bent clip ons. You only notice when put next to a straight one but it is there. Particularly the left one seems prone. 

Another thing you can do is Mark aka redrat sells some adjustable lock stops. They will give you marginally less lock if you cant sort the issue. 
Lastly refitting the tank tip. Loosen or remove the rear bolt and fit the fronts first then refit the rear. 

Looked at the lower dog bone and swingarm bearings yet? 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 19:31
Hi Wigginsjp,

Thanks for the kind words, I'm still at it.

I've only done 50 miles on the bike on a freezing December day, and haven't had to try a U-Turn on it yet. I'd seen the adjustable lock-stops, but was a bit concerned, can I afford to loose any steering lock?

The front of the tank seems to be trapping the headstock dust seal when I tighten it down too, I wonder if I'm missing a spacer or two somewhere.  Might fit a couple of small top hat bushed to just lift the front edge of the tank clear of the dust seal.  Or maybe the tank is just too far forward and that's why it's trapping.  I've taken the two rubber bungs out of the front of the battery box, and that's given me a bit more room to move the tank back and gain a bit at the front of the tank.

I continue to live and learn... I now know that later rider's seats may look the same as early ones from above, but they're different underneath on the front edge.  I'll have to pull the nice not-holey cover off my new seat and fit it to my holey-old seat.  Re-upholstery could be the future.

Front Brake Master Cylinder rebuilt and fitted tonight, with my lovely NOS Brembo Front Brake Lever, a steal at £35 and worth it I think, and a new Brembo Reservoir at £17, not worth it I think, but far better that the blue-anodised capped, rusty bolted, discoloured reservoir that was there.  Nice to have the right bits on yer best brake...  Front callipers to strip and clean before I can get any fluid in there.



I think the cable routing from left and right clip-on switch gear, throttle, fast-idle and clutch is just about sorted, looking tidy and no restrictions.

Steering damper "repair" attempted and failed.  It's better re-lubricated than it was, but still sticky, and probably not good enough.  It still sticks if left for a few minutes.  I'll go and see "reactive Suspension" and see if Gareth can pop a couple of seals and some new oil in it, already done the rose joints and cleaned it up.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 19:51
Getting there nicely I'm also enjoying the thread. You will continue to learn every time you work on it. This forum has given me the confidence to tackle any job now whereas before anything other than basic services the bike would of gone to a workshop.  You must have a very understanding missus with the amount of cave time you seem to be getting I generally work on my bikes in the daytime when no one us about Big smile
I started out with nothing and I've still got most of it left
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 22:04
I try and do an hour or so when I get home on a night.  She can watch the soaps while I play in the workshop.  I want the bike done in the next couple of weeks or so, so that I can get some miles on it and be comfortable about taking it to the island for a week in June.

The more I work on it, the more I like it.  I wasn't looking for an RSV, but I've got one, and I'm enjoying it. 😊
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 21 Mar 2019 at 22:07
Best way mate stuff TV its all crap I'd rather be riding or tinkering.  Ape bug bites hard im afraid,  I had always wanted one.  Now I've had threeBig smile
I started out with nothing and I've still got most of it left
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Post Options Post Options   Thanks (0) Thanks(0)   Quote IanG Quote  Post ReplyReply Direct Link To This Post Posted: 22 Mar 2019 at 08:12
Strange how things work out isn't it?         I never wanted one at all......and now I have two Smile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 22 Mar 2019 at 21:12
Originally posted by IanG IanG wrote:

Strange how things work out isn't it?         I never wanted one at all......and now I have two Smile
Hahaha we've all been bitten 
I started out with nothing and I've still got most of it left
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 23 Mar 2019 at 12:30
Up early this morning so did a bit before we went in to town.

Wiring to rear lights re-terminated, the hole that PO had drilled in rear tail light surround for alarm LED blank grommeted, new bulbs fitted, and everything cleaned up.  Tail unit and under tray back on, one of the fasteners on the pillion seat cover is broken off, but I think it'll be OK.



In other news, I've laced a short length of stainless MIG wire across the long side of the oval openings of my airbox boots, they're now rounder, larger than the openings in the frame, and line up better than they did.

I also stripped the front brake callipers, mucky 'orrible job.  The pistons and seals all look to be in good order.



So just the calliper castings to clean up, put it all back together, fasten 'em on and bleed.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote IanG Quote  Post ReplyReply Direct Link To This Post Posted: 23 Mar 2019 at 12:33
Looking really good there Clap    I do like a project coming good
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 23 Mar 2019 at 12:44
Thanks, but she's still a battle scarred Old Charger, I'm just hoping the attention will give her another lease of life.  Smile

Dropped the Ohlins Steering Damper off at Reactive Suspension yesterday.  Gareth wasn't in, but I've asked him to take a look when he has time.  The seals are a lot less sticky since I eased some oil inside them with a needle, but after ten or fifteen minutes static it was still sticking.  It might be that in use it's fine like that, but let's see how much Gareth wants to swap the seals before I decide what to do.

Oh, I've asked Redratbike if he's got any quick-release seat pins ready to go.

Back to my callipers now...
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 23 Mar 2019 at 18:09
My second-hand Brembo disks cleaned up and fitted (hope they're straight!?), front brake callipers back together and fitted.  They're not properly bled yet, they're resisting my will, but pistons have moved out and settled.  Maybe shoving them back will push the air up and out at the reservoir end...



And I will be dealing with the oil cooler at some point. Embarrassed
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 08:53
Front brakes bled, to the point where they're working anyway.  They're going to take another go to get them right.  Top fairing on, lights, indicators, brake and tail all working.



If I crack on with the rear brake master cylinder I can go for a ride round the block.  If it doesn't weave then either I've fixed the problem, or it was the steering damper.  I'd also like to know the front disks are straight.  And of course see if it's too loud as it is!

If all's well I'll make a start on the back end.  Rear brake calliper looks pretty rough, and I know the rear disk is shot.  I want to strip and check the rear shock linkage, fingers crossed there are no horrors hiding there.  And I want to get the rear shock off, cleaned and checked over.

After that lot there's the fairing panels to have a go at.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevex Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 09:12
You're going to make me feel guilty now, if it's not the steering damper!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 09:19
Don't worry Steve. I've changed so much on the front end, and any of these changes could've affected the weave.  So long as it's gone I'll be happy.

I got the grass cut yesterday, but it seems I may be going shopping this morning... Maybe I won't get out for that ride round the block after all. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wigginsjp Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 09:29
leave the damper off is a good way to see if it's the rear linkages causing the weave 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 10:58
Hi Wigginsjp,

It hadn't occurred to me that the rear suspension might also cause the weave...

As you don't actually need a rear brake, I've just been to the end of the drive and back.  Big smile

Before I have to go shopping...



Front disks are straight, that a relief.  I'll have a ride round the block when I get back later this afternoon, then go through the front end to make sure everything's still tight and correctly adjusted.

It's not too loud either, though that might change when the throttle's more open!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wigginsjp Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 11:19
Hi arlurt 

A very enjoyable thread and I'm loving the speed and progress you are making here. 

Ref the weave, it can often be caused by the rear dog bone not moving correctly. Or more the swingarm preventing it as they are the most commonly problematic. Had it on my gen1 and I had been 100% sure it was a sticky steering damper (as it was exactly how you described) until I took it off and I felt like I was in a slow motion tank slapper all the time. I then was told it was the head bearings so I had them replaced at great expense as I hadn't the tools.
I ended up doing the bearings on the dog bone and swingarm and it solved the issue. 

Luckily you are looking at all of that and with all your combined efforts and refresh it will be sorted! 

Top work 


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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 12:02
Thanks Wigginsjp.  I'm at the shopping centre, having a coffee and wishing I was working on the bike.  I've always intended to go through the bike end to end, and have seen the horror stories about the rear linkage. Are there problems with the swingarm pivot as well?

As usual I'll post pictures of whatever I find.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote IanG Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 12:11
Not always,but Luigi was a bit sparing of the grease when these bikes were built Confused

Hopefully his wife was better looked after   Wink

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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 14:01
Fifteen miles done, with no rear brake Embarrassed, and all's well!

No weave at any speed, so I guess it's not been caused by the rear linkage, steering damper still the likely suspect.

It feels very smooth with the FR200, modded collector, open can and airbox tweaks, maybe not quite as happy at very low (quiet) revs in traffic, but that's not a problem. Not as loud as I'd feared from some of the comments on here, I think I can get away with it so long as I show a little restraint when the boys in blue are close by.

I've backed it in the the workshop ready for the rear end investigation.  Does it have a grease nipple on the swing arm pivot?

I'll drop the shock and linkage and see how the swing arm feels with no load on it.

It's been a good day.  Even the tank seems to have settled down a bit, the top yoke now sliding over the top of the tank leading edge.

I guess the other thing to say is that there's nothing to say about starting problems.  It spins over like a good un, no doubt at all it'll fire up every time.  Thanks Johnboy for an excellent fix, so good you almost forget about it as soon as you've done it.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote IanG Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 14:36
Looking good

No grease nipple as standard but a few have modded theirs to include them,I was going to but expediency got in the way

You do get piece of mind with a set of John's cables and a decent battery,every bike should have them.

And also a decent stand and one of Mark's collectors,airbox mods like the open versions I'm not convinced by,I think people are mistaking noise for power in a lot of cases Wink

Early airboots and Edwards tubes are I think of benefit though
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 24 Mar 2019 at 16:26
OK, the back end is out, rear suspension linkage and shock on the bench.

The good news is that it came apart easily, and the rear brake pads are almost new!



The not so good news...  



The rear shock is leaking.  The shock bottom bush spacers are breaking up, corrosion I think, they're just crumbling.  The lower suspension adjuster is seized.  There's a bit of a knock in all the needle rollers, not too bad, and one of them is rust-marked at one end.

I'd guess someone's been in to it all for the last MoT, stripped, re-greased and cleaned up, and then stuck it all back together.  The needle rollers will stand a bit more grease, and maybe working the grease in will free up the rollers a bit and disguise the knocks.  I think the rollers aren't rolling, just staying put and sliding on the surface of the pins.

Everything moves freely freely enough, and I think the swing-arm bushes seem OK.

My (car) spring compressors are too chunky to be able to remove the spring, So I can't tell yet if there's any damping in the shock.  Maybe I can lash something up to remove the spring, but it's a dodgy thing to work on with improvised tools, there's a lot of potential energy in a compressed spring.  The sensible approach is to make it another job for Reactive Suspension, for which there'll be yet another bill.  There is a second hand Gen 2 Ohlins damper on eBay, are they the same as the Gen 1s?

So I guess I need some of these plastic spacers for the linkage...?

Why do you guys change the linkage side plates, is there something I need to know...?

Think I'll go for a beer or two and drown my sorrows.  Cry
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