My restoration

[BrettS]

Even better than grease would be antisieze.

[XSNT999]

Thanks Steve

I've just been thinking a little more about the whole process and I've remembered something I want to point out.  When I sent the bits off to the blaster I elected to leave the head stem bearings and swing arm bearings in place, they were taped up very well and I was hopeful of keeping the sand out.  The reason I did this was to prevent any sand damage to the bearing races and maybe have one less job to do, ie; not having to repack the bearings. WRONG!!!!

The sand got in everywhere and when I pulled the tape away the bearings had sand in them.  We live and we learn, so regardless of how well you prepare, double check everything and be ready to clean and re-pack bearings after blasting.

Another tip; if the blaster hasn't taped or plugged all threaded bits then run a tap or die through to clean the threads, also during assembly Mal suggests putting a dab of grease on all threads, it prevents problems if you have to take anything off later.

Cheers for now

[steveh]

FANTASTIC!!!

[XSNT999]

Hey everyone

Thanks for all your feedback.  I don't have the motor back yet, however the middle gear box has been painted and returned so I took a look and it has the same heavy duty cable that Ras has pointed out, so all is good.

Cheers

[BrettS]

Love the pictures and story Paul, I am taking it all in gearing up for my rebuild 

After the lack of earth was pointed out on my bike I did put a nice thick short earth on. Later I found what looked like an original earth in a different spot but it was loose so I have since tightened that up. So seems this may be in line with what Rasputin is suggesting.

[rasputin]

Not sure that there are not differences in the way your bikes ground (earth) but here is a pic of how the 2nd ground is mounted on all of my north american bikes. The first one does go from battery to frame and the third one grounds at the rectifier with a wire the comes from the gauge area. Hope this helps.

[XSNT999]

Errol, I will take a look tomorrow and double check, however there was only one cable to the frame but there is another wire also on the negative terminal that provides a link to the voltmeter in the fairing dash board, so hopefully everything will still work ok.

Cheers

[Eveready1100]

Paul, they say a picture is worth a thousand words, and I know of heaps of instances where problems have been avoided , or cured by someone picking up details in photos that have been  missed by the assembler.
Here's an example : I'm sure you will have read Bretts "Dusty" thread where he was having electrical problems with the bike about 1/4 the way through the epic story. Well, I'm getting a sense of Deja vu here because in his case, it was picked up that his main ground wire to the motor wasn't there -


 ^ Brett's bike photo from page 10 of his thread

Now I've just seen this one of yours -



And I'm concerned about your earth cable/s. Should be two of them coming off where your red lead is bolted. One to the battery negative, and the other to the rear of the gearbox.


 ^ This is Jonesey's photo of the earth cable on his bike. (you can't see the other one under it but trust me, it'll be there somwhere. These earths are vital to the well being of the electrics on these bikes so just have a look to see if there is a loose cable lying around anywhere.

[XSNT999]

Hi Errol

Thanks for the offer of photos, I never thought of that, what a great idea, if I get stuck again I'll put out the call.

Cheers


Hi Eddy

I'm glad you're inspired again, that was part of the reason to post this story to encourage anyone who is having doubts about tackling this sort of thing.  I will admit the process has been easier with Mal's help and I may not have taken it this far without his backup and enthusiasm.

Cheers

[XSIIE]

Nice work paul,

I started my rebuild Chrissy 2011 and have only got the swing arm on the newly painted frame.  You're miles ahead of my rebuild.

You've enthused me to get photos up and to pull my finger out.......

Cheers

Eddy

[Eveready1100]

Great work so far, Paul! Progressive build threads are a favourite of mine, so you've certainly got my interest.

One thing I will say at this point is it's quite easy to pull things off the frame and I was taking several photos as I went along, however I didn't take ENOUGH.  The older one gets the less you should rely on your memory, as the rebuild was taking place I would have loved to refer to more photos to remind me of where everything went.

Regarding this bit, if there's any spots you have a doubt with, just ask the question and I'm sure any number of fellows on here can take photos of their bikes in the area of concern and post them up for your reference. We're all here to help in any way we can.

Keep up the good work, mate.We'll be watching over you.

[XSNT999]

The problem is sorted it seems.











That's where I'm at now, I have put the gearsack frame on along with the airbox but haven't taken a photo yet.

I have found this process to be very enjoyable, especially not having to worry about going to work, you can work at a more relaxed pace.  Due to many of the components coming back looking like new I have found that you work a little harder at making sure it's right and looking good before it goes back on.

Just another reminder about photos, take heaps, it will always pay off, in this digital age you can print them off anytime and it certainly helps to have good references when your memory fades.

The journey continues and I will post more photos as I make progress.

I feel more confident now about the trip to Bourke. 

Cheers

[XSNT999]

I now have the wheels on and have rolled it out of the shed.





I'm having some problems with downloading the rest of the photos so I will post these and come back to it.

Cheers

[XSNT999]

The rebuild begins:

I pulled it all apart during Dec & Jan and gave lots of parts to Mal Pitman who organised to have wheels, brake components and the engine cases painted in a satin black.  He also cleaned up and nickel plated all nuts & bolts and many other parts and believe me they look great.

During Feb I had the frame and several parts sand blasted and painted in two pack black gloss, also the exhaust headers were blasted and painted in heat proof black.

I got all the pieces back on Sun 3rd March just as I commenced long service leave, they say timing is everything.

I then laid it all out on a table and commenced putting it back together.


















A bit of elbow grease and 3 grades of wet & dry paper produced a good result and I like the look of my forks now.







Getting the new rubber grommet on the brake plate was fun, lots of patience needed there.



This looks a lot nicer now.







still more to come

[melbxs]

Great work. Very much looking forward to seeing it all come back together.