Erica Gets Some TLC At Long Last

This week, I turned my attention to Erica again at last.

I remembered the box of parts I’d been given contained a spare set of headlight mounting nuts.

In order to fit them I of course needed to remove the retaining screws from the bottom of the headlight rim.

I removed the headlight and unscrewed the temporary bolt from the left side of the headlight (the right side when facing the bike)

As I used 13mm hex head bolts and nuts to replace the missing original bolts, I had to switch spanners from the normal 12mm or 14mm sizes normally found on Japanese bikes to remove the temporary washer and nut.

I fitted the mounting nut on the right side and moved onto the left side.

I added the temporary nut and washer to the pile of spare parts.

I fitted the left side mounting nut. I’ll need to solder another wire to this one at some stage to replace the one that was cut off.

While working on the headlight mounts, I noticed the right front indicator wire had a bare solder joint, so I removed the indicator.

I decided I’d also replace the indicator mounting post, as the spare indicators came with those too.

I loosely attached the replacement indicator and plugged in the wire.

I removed the indicator from the mounting post in order to fit the post before reattaching it firmly.

I noticed the indicator lens had some scratches on it, so I found the least scratched one from the spares.

I mounted the spare lens and screwed it down tight.

I put the old indicator  on the post and left it with the spares.

Erica’s starting to look quite smart from the front now. Hopefully the changes to the electrical system help sort out some of the gremlins!

That’s all for this week. I’ll charge her battery again and see if it’s made any difference soon.


Re-Covering Sylvie’s Seat Again, With Limited Success

This week, I decided to re-cover Sylvie’s seat yet again, as the cheap non-slip matting had worn out quicker than expected from the grippy section of my motorcycle pants.

I took the seat off in order to remove the previous layer of covering.

I decided to try a different type of PVC rubber non-slip matting this time.

I removed the previous cover and checked the extent of the wear.

The previous layer below was still in good shape, apart from the small patches of duct tape and the impression from the layer above.

I ued the previous cover layer as a template and cut a piece to size.

I set to work with the staple gun and  soon discovered that this type of matting was less stretchy than expected, so I was not entirely happy with the result.

I finished it off with black duct tape until I have time to cut another piece

I popped the seat back on Sylvie, as I need to ride her this week and don’t have a spare seat.

While I’m not entirely happy with the result I like the finish on this material, so I will use the remainder of the roll to make another cover. I may even get adventurous enough to cut several pieces and sew them together…

That’s all for now. I’ll see what I can come up with for next week’s update!

How Not To Remove A Flywheel

Just a quick update this week, as I had other things to fix unrelated to my hobbies.

This week, I decided to try my luck with the flywheel puller and removing the flywheel from Rosie.

I started by making sure the thread on the puller was well greased.

Unfortunately it didn’t help, as the puller just wouldn’t thread properly in the stripped thread.

I did succeed in stripping the thread on the puller, however.

Next week, I’ll be working on Sylvie and maybe Erica or Scarlet, time permitting.

Returning to Rosie – In Which I Chase A Dropped Part And Break A Socket

With Sylvie both not in need of immediate attention and generally running well, I finally spent some time working on Rosie this week.

What type of bike is Rosie, new readers may ask?

Rosie is a KLR650 I started a top-end rebuild on some time ago. Unfortunately, I wasn’t as careful not to drop any parts back then and I managed to lose a part down the cam chain cavity, so she’s been half-disassembled for several years.

The parts had been moved from one bench to another and had gathered a layer of stuff on top.

The first step was of course relocating said layer of stuff.

Rosie’s original fairings have faded to a rosy pink from the factory red, which led to her name.

One of the front side fairings has been replaced by a previous owner so the decals seen on the other one are missing completely.

I’d decided to take the side cover of the motor to retrieve the lost part some time ago but had never finsihed, so I resumed the process this week.

The cables attached to the stator ran behind the front chain guard.

After a quick reference pic, off it came!


I’ll give it a bit of a clean before putting it back on.

I rested the stator cover on the footpeg and the brake lever.

I carefully removed the outer gears and bearings.



The part that had fallen down looked to be stuck behind the rotor, so I set about preparing to remove the rotor.

The centre mounting bolt was quite tight.

It took a fair bit of convincing but I was eventually able to loosen it.

While the bolt seemed undamaged from the removal effort…

…I can’t say the same for the first socket I used on it!


I realised I would need a flywheel puller, so I repurposed the inner bolt from my old chain tool that had a damaged thread.

The thread on the end had been damaged by a misplaced spring when using it but a few minutes on the bench grinder took the burrs off.

It fit very well in the hole for the mounting bolt.Eventually I realised the flywheel puller needed to go in the outer thread though!

Fortunately I remembered that I had bought a suitable flywheel puller some time ago and had never used it!

This one had an M22 thread, which is the exact size I should have needed.

Unfortunately, I found was that someone had stripped the thread inside the rotor when it was removed at some stage in the past!

That’s all for now, until I figure out how to remove the flywheel without a puller!

I’ll have a look at what can be done on the other bikes if I can’t find a solution in time for next week’s update…

A New Tank Pad For Sylvie

This week, I set about removing the old tank pad from Sylvie to replace it.

The old tank pad had become quite brittle and was hard to remove, so I used the hard plastic blade of an old fan as a scraper.


I also used some heavy duty textured wipes to clean off the glue and remainder of the sticker.under the brittle clear layer.


It was slow going but I finally managed to clean off all traces of the old tank pad off.


I gave the tank a final wipe over and let it dry


Finally, I applied the new tank pad.


While the new tank pad looks very similar to the one it replaced, I’m hoping it’d better quality and that it lasts a little longer than the old one did!

That’s all for this week. Next week, I hope to return to working on either Rosie or Scarlet.

Khaleesi Goes Home At Last And A Temporary Floor Is Placed

Just a quick update this week, as I made the final adjustments to Khaleesi’s chain this week and her owner came over and collected her, freeing up some shed space at last!

The shed floor under Rosie had been slowly bowing, so I took the opportunity to move her out and placed a piece of scrap particle board flooring over the bowing.

I put Rosie back on the centre stand and found the scrap of flooring held her weight much better.

I tidied up the space where Khaleesi had been.

Finally, I moved Scarlet back into the shed.

That’s all for this week. Hopefully I’ll have time to start working on these two bikes again soon!

Filling In The Cracks – Work On Khaleesi Nears The End

This week, I finished up most of the work on Khaleesi.

I started by cleaning up the shed and sorting the pile of old parts from Khaleesi

I found my J B Weld and mixed up a small amount.

I filled the cracks in the bottom of the engine casing and put a thin layer around the bottom to keep the cracks from spreading further

I checked the charger and found that the connector was connected to a circuit that had  some sort of overload that didn’t work with my charger, so I took the side cover off and attached the trickle charger’s clips directly to the battery.

Finally I tightened the front sprocket nut to the specified torque and replaced the front chain guard.

I didn’t have any suitable oil to top up the lost oil, so I’ve let Khaleesi’s owner know and he’ll top it up.

The two remaining tasks are to to tighten the gear shift lever bolt and loosen the chain a little and she’ll be picked up next weekend.

That’s all for this week – hopefully I’ll have some time to work on my own bikes again in time for next week’s update!