Thumper Club Forum
Technical => Project Progress => Topic started by: Ian on October 20, 2024, 11:16:06 AM
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Having sold my Black and Gold SRX earlier in the year to fund the Triumph Speed400 (which caused a lot of interest at the Stafford Show), I thought I would have recovered from the motorcyclist's disease "Gottohaveanotherone". But I was so wrong! I saw that "returning Simon" had an electric start one that he bought for spares would be up for sale due to relocation. I duly went to see it and purchased it a couple of days later. The bike seems generally complete and unmolested but there are a few bits I will have to get from Japan.
First job I had to do was remove the front forks as one of them was seized, (the bike having been stood for 7 years).
The unseized fork leg came apart quite readily, but you do need an extended tool to hold the piston whilst undoing the fine thread bolt at the base.
The seized one was a different ball game altogether. I undid the bottom bolt, but the slider and outer leg would not part company. Many attempts were tried and at one point 3 of us were on it trying to separate them. Eventually I had to compress the fork leg as tight as possible, hold the chrome slider in the 3jaw chuck on my lathe at work, insert a revolving centre and carefully machine the offending oil seal that was preventing disassembly. It finally succumbed after about 2 hours work in total trying to pull it apart.
I will need to get the sliding legs re hard chromed, new seals and dust shields, new spacer washers and fixed top bushes. These are split bushes and readily available. However the bottom bushes do not seem to be available at all so I will have to machine new ones possibly from Aluminium Bronze. These are split ones also and will be a bit more awkward to make. Enclosing (hopefully) a couple of pics.
Onwards and upwards!
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Few more photos. Bottom of "seized" fork leg, seal spacer washers: good on left, bad on right. And bottom bush out of seized leg.
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Aye Ian,
A glutton for punishment! ;)
That'll keep you busy for a while and the postage costs + other taxes from Japan are horrendous. :'( All the best with it and regards to Simon.
Good health, Bill
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Just "won" 2 auctions on Jauce Japan
248 Yen for 2 airbox covers
207 Yen for a chain guard
(Approx 185 Yen to the pound)
Yes I know there are taxes etc but I still feel a bargain for parts that are very rarely available in UK
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Aye Ian,
I would agree that you are getting some good deals, with those auction wins. Hope that you get some more, if required.
Good health, Bill
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Few more photos. Bottom of "seized" fork leg, seal spacer washers: good on left, bad on right. And bottom bush out of seized leg.
Have you tried the bushes out of early FZR 400/600 forks ?
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Few more photos. Bottom of "seized" fork leg, seal spacer washers: good on left, bad on right. And bottom bush out of seized leg.
Have you tried the bushes out of early FZR 400/600 forks ?
What do you call early Steve? I was going to machine new bushes from Ali bronze🤔
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Not sure but I have 38mm FZR stanchions with 3VN sliders and yokes fitted to one of my SRX's. The stanchions are longer then the 3VN ones so you are better of with those, but the bushes may fit
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you do need an extended tool and to pull it
Onwards and upwards!
Ooo eerr ...more tea vicar
Just seen this thread, sounds interesting Ian and I’m sure if there’s a man capable of turning (see what I did there😉) out a superb finished bike it’s you. I look forward to hearing more once you get cracking on it. Best of luck with it 🤞👍
Cheers, Michael
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Hello Michael, nice to hear from you again.
Progress so far:-
Frame etc away for S/B and powder coating
Paintwork away being sorted....hopefully finished very soon
Switches repainted, new letters procured.
New (old) headlamp obtained.
Fork Stanchions away being rechromed
Chain guard and airbox covers obtained from Japan
Loads of little jobs done.
Will post more as I do them
👍🏍?👍
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Sounds like you’ve been very busy beavering away already Ian.
Look forward to more photos when the timing is right👍👍
Cheers, Michael
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Just a couple of photos of the remade "Dashboard" showing new wiring harness and GPS Speedometer. I'm using this as I will be unable to use the original Speedo (due to lack of space for a cable).
Renthal number 755 medium bend handlebars being used again. I used the original pair on the Speed400 so had to repurchase 🙄.
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Repainted switch housing with new letters, they have since been lacquered and rebuilt. I used to use "Letraset" but these are now "no longer available". I have sourced new letters but they are vinyl and a lot thicker but still useable.
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All looking tip top Ian. Looking forward to the next set of photos 👍
Cheers, Michael
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Aye Ian, very swish, my compliments.
Good health, Bill
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All looking very nice. Glad someone is progressing!
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All looking very nice. Glad someone is progressing!
Progress comes to a halt.... "bu99er!".
Powder Coater picked the wrong colour for the frame, sprayer made a mess of tank stripes......both back there awaiting reparations.....such is life ??
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The wheels are looking good tho 😂
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Glad to see you making something of it Ian. The gos Speedo looks interesting. I did wonder if you would go for upright bars. Our good SRX you saw came with rentalls on a drilled yolk but I put clip on back. All the best.
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The wheels are looking good tho 😂
Niiiiiice 👍👍
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Trial assembly
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Aye Ian,
OOOOOooo! VERY sparkly and festive! 8) 8) 8)
Top yoke used for handlebars? Or is it a standard yoke modified?
Thank you for posting. I have been out watching Pink-Foot geese, as we have large flocks of over 2,000 birds feeding and roosting around the house at present.
Good health, Bill
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Very observant Bill 😉. Top yoke & headlight bracket off an XJ600N. Tachometer is original as is the ignition switch. Speedometer is GPS as no room for a Speedo cable. I will machine a spacer for the front wheel to do away with the speedo drive. Headlight off a Suzuki GS500, via fleabay, as the headlight that came with the bike wasn't good enough for me to use.
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Aye Ian,
Thank you for the info on the top yoke upgrade for handlebars.
Good health, Bill
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Yes, all looking good Ian. I notice you either have a very nice tiled garage floor OR an extremely understanding wife that lets you build your bikes in the house 😉
Looking forward to to the next set of photos 😁👍
Cheers, Michael
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Yes, all looking good Ian. I notice you either have a very nice tiled garage floor OR an extremely understanding wife that lets you build your bikes in the house 😉....
I am allowed to start the build in the conservatory. The garage has just been re carpeted so I didn't want to get it dirty ....😁😁😁
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Further to the Fork (lower) bush saga..... I started to machine replacements out of Ally bronze. I was really struggling to get a good enough finish and maintain the size. Then as if by magic, I had a recommendation on Fleabay for replacement bushes from someone called AW Motorcycles in Doncaster. They are manufactured by a company called Hendler. The exact sizes I wanted, plus to me, indistinguishable from the originals 😁 Added bonus was 10% off the price 👍
Shown in the photo from L to R
My effort, the original, Hendler replacement
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It's sometimes very hard to get a decent finsih when turning. External's not too bad as you can polish with emery but internal is tricky.
I think I bought some Hendler rear suspension units a few years ago - nothing special but cheap and worked.
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. The garage has just been re carpeted so I didn't want to get it dirty ....😁😁😁
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🤣🤣🤣..... that’s the spirit 👍
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A few more photos. Progress has been hindered by the fork stanchions episode.
Wheels with new tyres and rear one with new sprocket 43T (520 chain)
Front side panels painted and JPS decals which I found left over from previous resto. These need satin lacquering (just arrived)
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A few more photos. Plating just done this week. Footrests not refitted as new were purchased cheaper than replacement rubbers. These are identical to the previous resto items.
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Last few pics for now. Rear wheel spindle, again just plated this week. Close inspection shows how many parts are involved. The rear chain adjuster plates need painting on the outside face, but will get done this week. Paintwork has been completed a few weeks now. Stripes painted instead of decals this time, colour matched to frame colour.
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All looking tip top Ian. Although I wouldn’t have expected anything less to come out your garage. (Especially given it’s got a clean carpet in there 😁)
Looking forward to the next instalment of pics 👍
Cheers, Michael
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Top pocket job! Looking good Ian. No rebuilding going on at present, been running the Duke about and now that the ice and brine have taken hold, the garden, firewooding, and a bit of agate work along with the genealogy has taken over.
Rest assured the steeds have not been forgotten!
Good health, Bill
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Soon be time to leave the nice warm conservatory. 😭
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I see you've installed the airbox afore the engine, unlike myself! ::) I then had to lift the engine in and out on my own, whilst inserting retaining bolts that were well copper greased! I'll nae forget, if I have to do it again. ;)
Is the support that you have in the lift specific for the SRX monoshock, or is it adaptable for other machines?
Good health, Bill
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Bill, airbox first always!
My bike lift is supposed to lift the majority of bikes up to Triumph Rocket 3 (think!). I haven't tried it yet. I bought the additional kit to fit to the footrests. It wasn't cheap but I use it quite a lot.
https://on-bike.com/motorcycle-lifts?filter_product-type=eazyrizer-original-red
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FRiENds reunited (FRame & ENgine).....ha ha
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Aye Ian,
Tidy! ;)
We have the same lift Ian and I suspect the same attachments, which make it very adaptable. But, I wish I knew how many people stored it by "hanging it on the garage wall", as advertised. Hernia comes to mind and I would knock my head on the post in the passing.
Steady away.
Good health, Bill
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I wish I knew how many people stored it by "hanging it on the garage wall", as advertised. Hernia comes to mind and I would knock my head on the post in the passing.
Steady away.
Good health, Bill
I asked myself those very same questions Bill.
Poor advertising at best.....
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Couple of pics....
Noisy exhaust made quieter by making a decibel killer.
Front caliper (courtesy of an early FZ6) No mod required.
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One more photo:- Rear caliper fully rebuilt and painted
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Just waiting for tank to be sealed then I can fit it, get it insured on the VIN number, get an MOT and register it with DVLA. Dating certificate and NOVA Certificate both obtained, just need the MOT to complete the documents required 🤞
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Looking very nice Ian, as we’ve come to expect from your builds 😉👍 look forward to seeing the final pics of it completed
Hopefully you can get all the paperwork & MOT sorted without any hiccups then get out in this glorious sunshine.
Cheers. Michael
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Aye Ian, looking very pukka, I hope the paper work all goes smoothly and you can get the beasty out for a canter in the spring sun.
Thank you for posting.
Good health, Bill
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Michael, as requested, couple more pics of (virtually) completed bike. Just a bit of detailing to do. Seat "cowel" is for Mr MOTer's benefit. It will be removed for normal use 😂
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Another pic.
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Looks brilliant Ian. Hopefully the weather holds out and you can go “roarting” off down the road on it. Bet it sounds well with that neat little exhaust 👍👍
Cheers, Michael
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That's a damn pretty motorcycle you have created there sir.
Ian
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Thank you for your lovely comments. This one has been an exceptionally frustrating restoration, due to exorbitant increasing of prices of original parts and trying to get work done that is beyond my capabilities.
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Yes... but hopefully all worth it in the end Ian. Cracking looking bike😉👍
Cheers, Michael