Put in a pretty long day in the shop today. Seems like I don't have a lot to show considering the time involved but some steps forward no less.
Started by taking down all the plastic and de-murderizing the room. lol
Decided it was time to tackle the master cylinder rebuild since it is now painted and cured a few days.
Rebuilt kit.
First pull off the rubber dust boot. Sick.
Then there is a wire ring in there that actually holds the rubber boot down. I didn't realize this and was going straight for the snap ring.
Long reach snap ring pliers... they're actually not that great. The tips bend if you press too hard.
Finally noticed that the other metal snap ring and get it out first.
Trying to gain some access to things but holding the plunger down with a clamp/bolt.
Dust boot/metal retainer.
Now I can attack the snap ring.
After much farting around I got it out.
Victory! I thought...
I had to battle for this step too. The washer was seized into the MC bore so it didn't just pop out like it should have when I got the snap ring out. I was confused because I wasn't sure if there was something else holding it in. After some research I concluded that I just need to yank the fvcker out. Done and done. lol
Yummy!
And it only took this many tools...
The bore is fairly clean its just where the snap ring was that was grungy.
All the spoils laid out in order.
Cleaned up with some steel wool.
Intermission parts pickup run/NAPA run. New side covers and rear grab bar that I bought from Scotty J. Thanks man!
Stopped at NAPA for some assembly lube but ended up with a bit more...
I decided to put my parts through the dishwasher for a couple reasons: 1) It would give them a final cleaning before assembly. 2) The drying cycle will harden the paint some. 1 thing I didn't expect was the flash rust on the steel parts!
All these items went through the dishwasher. The cases were in the dishwasher when this photo was taken. My gf is very understanding. lol
Scotchbrite takes care of the rust.
Lets assemble this thang!
I didn't bother to heat the hub or freeze the bearing... 2x4 and a hammer gets the job done though.
Don't forget the bearing spacer.
Other side bearing goes in. Used the axle to help keep them aligned and ram it in.
Got the retainer in and lined up the marks and re peened them.
Install the cush drive rubbers and put some lube on them to help assembly. *NOTE* At this point I should have put the shouldered spacer over this bearing before putting the hub cover on. This shouldered spacer makes sure that when the axle is torqued down that all three bearings are pressed together. It maintains the bearings stack up. I forgot this part and ended up taking it apart again after to replace it.
Old seal out of the retainer.
Cleaned up with new seal, in and re-peened.
Ta da! Honestly, this thing is heavy! If a guy was looking to shave some weight I'm thinking there has to be some extra in here....
Sprocket will have to come off again later but on there for now just because.
Old parts and some reference material got the job done.
Back at the master cylunder now that it's out of the dish washer! *Note* I have the seal on the plunger incorrectly in this photo! I put it all together and it was binding up... should actually be between the two pistons.
Use a little brake fluid for lube.
Had some troubles assembling ... MC would bind up once the snap ring was in. I had the seal on wrong. Now it's on correctly.
Spring then rubber spring cover then plunger with seal then washer then snap ring.
Dust boot with seal in place.
On to the front hub. A skiff of grease and socket drives it in.
2x4 gets the job done on the other side.
Out with the old seal and in with the new.
Retainer back in and peened in.
I got a bit carried away... can't actually put the rest of this stuff together until my disc gets back from cycle x. Oops.
Anyone know what this seal is for? It doesn't look like the right OD to be the speedo seal.
Rebuilt!
I didn't get my shock bushings in my swingarm all the way in last time so I bought some longer bolts and this drove them in the rest of the way.
Took the advice of another member and installed the brake arm now while access is good.
Greased up the swingarm bushings and installed the pivot with new dust felts.
New thrust washers.
And finally re-zinc'ed caps.
Installed the swingarm ... incorrectly. lol It has to be about those supports.
Much better.
Got the shocks on.
A view from my vantage.
Starting to come together and look like a bike again.
Clean up and put away some #$%*. You can see the cases in the corner. Nice and clean out of the dish washer. No blasting grit to ruin my bearings.
Bikes got some mean rake with no front wheel. lol
So as you can see I got a bit done today. I thought all these things would take less time than they did but ... you know how it goes.
IW
