Last weekend I went through the very final stages before Scarlet’s rego inspection.
First up – rear brake shoe replacement.
To replace the brake shoes, I needed to remove the back wheel.
This meant removing the split pin from the rear axle nut first.
The multi-grip pliers from the onboard toolkit were just the tool for the job!
In order to get to the rear axle without major space issues, I took the mufflers off.
I figured it would be a good time to fit the exhaust gaskets and replace the missing nuts for the exhaust mounts too.
The nuts came off easily enough
The clamps and flanged nuts for the mufflers. The nuts are 10 mm, for those of you playing at home.
The rear mounting bolts also hold the pillion pegs on.
Mufflers off – these bolts are 14 mm and needed a socket wrench to remove easily.
Once the mufflers were off, I had more room to work.
I took off the rear chain case to make it easier to remove the chain and made a mental note to replace the missing chain case bolt.
Next up I removed the front chain cover.
This chain is a non o ring chain with clip master links. We’ll come back to these.
Before I removed the chain, I loosened off the chain tensioning nuts
The rear brake assembly was next.
I also removed the bolt form the rear brake stabilizer bar.
I removed the axle nut – this one is 22 mm. I realised later that I didn’t need to remove it, just loosening it would have done.
Finally the chain itself could come off. I pried off the clip from the master link with a flat-bladed screwdriver, removed the plate and the master link came out easily.
The chain ready for cleaning.
A closer look at the components of the clip-style master link.
I put the chain in an old plastic bucket and soaked it in kerosene while I removed the wheel.
I loosened off the chain tensioners a bit more until I could swing them down enough to remove the axle retaining plates
The wheel lifted out easily. I took a couple of reference photos so I could see how it went back together after disassembly.
The brake shoes were pretty worn.
The new ones are on the left, old on the right.
Fitted the new brake shoes.
After starting to reassemble the axle, I realised I didn’t have the shoes lined up correctly. They should be flush as per below.
A bit of axle grease to go with the elbow grease involved in all this work!
Reassembly – looks like everything is on the right order!
Lifted the wheel back into the slots on the swingarm and greased the retaining plates before putting them back in.
Swung the chain tensioners back up and tightened the axle nut to hold them in place.
After scrubbing the chain with a toothbrush it’s noticeably cleaner.
Threaded the chain back through the front sprocket and reassembled the master link on the rear sprocket.
A flat-bladed screwdriver is very handy for pushing the clip back on.
At this point, I was ready to put everything back together, until I noticed the damaged plug from the left crankcase cover.
This could have been a major cause of oil leakage and is pretty much not what I want to see on a bike I intend to ride!
Luckily the left crankcase cover from Bruiser was in great condition!
To take this cover off, I needed to remove the gearshift pedal.
Out came the sump plug.
Good thing I had that bucket handy from cleaning the chain!
Once the oil had drained, I removed the cover. As the stator is attached to it, there was a fair bit of magnetism holding it on.
Stator mounting bolts removed.
I figured I might as well replace the gasket while the cover was off. Luckily, I’d already bought a complete gasket kit in expectation of a complete motor rebuild. The replacement paper gasket is at the top, the original plastic one at the bottom.
Bolted the stator onto the replacement crankcase cover and put the sump plug back in before reassembly to save time.
I noticed some corrosion/crud in here and cleaned it out before replacing the cover.
Put the new gasket on.
When replacing the cover, I replaced the washer over the gear selector axle before easing the bottom corner of the crankcase cover onto it.
While replacing the crankcase cover, there was a strong magnetic attraction that “sucked” it into place.
After bolting on the crankcase cover and lower chain guard, I reconnected the neutral switch wire to the neutral switch. It’s held in place with a spring and washer.
The collar for the neutral switch was missing, so I used the one from Bruiser, then replaced the gearshift pedal.
After refilling the engine oil, it was on to the chain. Out with the trusty chain oil!
After oiling the chain and sprockets, I replaced the front chain cover.
Adjusted the chain tensioners to approximately matching settings.
Reconnected the rear brake stabiliser bar and brake pedal
Tightened up the rear axle nut and replaced the split pin.
Finally, I moved on to the exhaust gaskets. At first I thought that there were no exhaust gaskets fitted but they were just completely crushed. The old gaskets are at the top, the new ones are at the bottom.
The new gaskets were a tight fit, so I tapped them in place with a hammer and the extension bar from Scarlet’s toolkit.
I replaced the flange nuts with the new ones from the engine bolt kit I bought months ago but never got around to using.
Bolted the rear mounts back on with the pillion pegs.
With the mufflers replaced, it was time to start her up!
After a quick run in neutral to test her performance, I decided to give her a polish with the towel I’d mopped up the spilled 20W-50 with while replacing her oil. She came up a treat!
Unfortunately after a quick test ride, I noticed that while the speedo seemed to work, the odometer didn’t. As I’m planning to take her on some long road trips, this could be an issue!
I swapped the speedo for another one that had a broken needle and broke both the tacho needle and the speedo needles in the process. The tacho needle was able to be glued back together but the speedo one broke so thoroughly that I replaced it with a piece cut from a broken translucent orange plastic box I had. It’s on my list of “things to fix longer-term”.
The good news is, she passed a rego inspection today so will be registered as soon as possible!