www.DRRiders.com

Started re-assembly today. First job was to weld some extensions to the legs of the stand and then clamp the frame to it. Hopefully it won't fall over



Threw the swingarm and linkages into place with the KLR650 shock. Almost looks like it was made for it







Don't plan on crawling over any logs or rocks, so the extra length of the lower mount shouldn't cause any problems....



Until next time...

.....Love the look of a freshly painted frame! What a world of difference.......

Yep, looks much better! Bolting everything on without chipping or scratching the paint is difficult!

Haven't done much lately as it gets too damn hot in the shed during the day. Had to pull the speedo apart to clean out the hornet nests and saw the remains of metal rubbing on metal:



The culprit was the part that the cable attaches to, which had worked loose and caused the spinning magnet thingamajig to rub on the needle shaft whatchamacallit. Notice the gap.



Cleaned it up and glued it with liquid steel:



Tested it by turning it with a drill. My cordless runs at 20km/h and the electric does 100km/h Had to get it working to pass the inspection before getting it registered. When it throws in the towel I'll replace it with a Trail Tech.

Put everything back together and mounted the panel.



Also blasted, primed, painted and baked all the lever mounts and throttle housing, and mounted them to the new bars, along with the N.O.S switches. Both sourced through Ebay; One came from Germany and the other from Israel.



Going to try and split the engine cases this afternoon. The crank will be sent away to have the new rod, pin and bearings fitted, third gear will be replaced, as well as all bearings. When the project is finished, it will be a 22 year old brand new bike

Cheers,
David.

It doesn't rain, It pours..

Split the cases with no problems, and found more evidence of bad maintenance. Sigh...



The drive gears (top of photo) are the worst, but I may be able to get away with using the driven gears again. Need to get a second and third opinion before deciding. Just purchased both 5th gears (NOS) for $65 from the UK, which saved me about 130 bucks.

Time for a beer (or six)

Back at work again, so progress has slowed down a bit. At this point the main focus is cleaning and re-assembly while waiting for the last lot of engine parts to arrive.

The guts of the speedo drive cleaned up for installing the Hessler drive gear.



The headlight lens looked a bit sad and had what appeared to be tape residue on it.





Turns out the plastic had UV light deterioration, so I searched for some way to restore it as I didn't want to pay $350+ for a new complete light. Used the procedure shown here: http://www.techguys.ca/howto/polish_lenses.html However, I could not get the cleaner and polish locally, so I used Meguiar's Motorcycle Plastic Polish.

Halfway through the sanding process. Hope it works, because it's unusable looking like this!



And the end result. Much better



The reflector is also in a sad state, with rust on the bottom and burn mark from bulb heat (?) on the top, so will have to be sent away to be re-silvered.



Now for the fun job of sorting out the wiring....

It's a non venomous Children's Python and this one would be about 3.5 ft long.

Cheers,
David.


I would have shite my pants for sure if opened up a drawer in my shop and found this!!
In some ways I am thankful for the cold climate here that does not always support critters like that.

no doubt this is looking more like a 'restoration' than a rebuild.....

What was required to mount the KLR rear shock? Looking to beef up my rear suspension on my 91 and there don't appear to be any real options.

Just had to get some bushes made for the top mount bolt (12mm down to 10mm) and drill the bottom yoke for the lower mount bolt. This is the cheapest option. The other options are Hagon, YSS or Betor in the $300 to $400 range, Wilbers for around $500, or Ohlins for around $900. I'm a tight arse, so I went for the cheapest option

PuntoMX from ADVrider did it first.

http://advrider.com/forums/showpost.php?p=13424337

Cheers,
David.

Finally an update! Don't ya hate it when real life gets in the way of a hobby Nothing too exciting to show, but thankfully the finish line is in sight!

Headlight reflector after Metallising. It is not perfect because the first step in preparing reflectors for coating is buffing to remove rust, loose material etc and the buffing wheel was too large to fit inside. Looks as good as a new one, and was much cheaper too!


Centre cases bead blasted and ready for painting:


And painted:


Barrel and NOS head ready for paint:


The machining of the head left a couple of ledges at the top of the ports, so I attacked them with a stone in a die grinder.
Before:


After:


Head painted and ready for assembly:


New valves, springs and retainers:


Lap, lap, lap :


And finished:




New rocker cover (came with the head) rockers, rocker shafts, thrust washers, seal, and painted decompression parts:


New Hel Performance front braided brake line, which is "supposedly" a direct replacement for the original. The original bracket could not be used, so I made a new top bracket out of some scrap stainless plate I found at work:


Made some new stainless steel washers for mounting the front fender. I used a mate's lathes to do the work, which was the first time I have used one:




Almost finished. Just need some filing to remove burrs and smooth the top. The original washers are on the right:


That's all for now.