Quick Update – A Tap For Rosie’s Stator

Just a quick update this week.

I got a parcel!

Inside was a 22mm diameter 1.5mm pitch right hand thread tap.

Not sure if you can see it in the pitcure but the warning label reads more like poetry!

1 In the work of prohibition gloves.
2 reasonable selection of feed rate,
tool grinding angle to make the Iron
cut pellets, prevent Iron cut hurt.
3 prohibit the operation removing Iron
cutting. Workpiece contact.
4 forbidden operation.

I bought this to try cutting a new thread for the flywheel on Rosie and hoping I could also use it instead of the puller.

It turns out that I can’t get good enough torque once the tap is through the hole, so I’ll have to try replacing the puller or grinding it down past the damaged thread.

I’m not sure the thread will be strong enough to allow the puller to disengage the flywheel at this stage, so I may need to invest in a diferrent type of puller further down the track!

That’s all for this week, more to come in a week or twodepending on time!


Unboxing And Filling A New Toolbox, And The Future Of The Vlog

It’s been really hot in the Australian summer lately, so I didn’t get a lot done over the New Year break.

I did unpack and start filling a new toolbox though, here’s a video about that and the future of my vlog series:

Here’s the toolbox when I first unpacked it.

I started by picking up all the loose spanners.

II moved things around quite a bit and the spanners ended up in the top drawer.


THe old toolbox is more suited for general DIY and is a lot smaller!

I placed a board on the wire shelf to give the toolbox a bit more support.

It’s a lot more stable now, and easier to get to than the old toolbox

As far as further updates go, this blog was only ever meant to be a way of sharing my hobby with my friends and anyone else who may be interested. Facebook changed the rules for automated posting from WordPress blogs so I created a Page, which now nags me to update regularly. I then put further pressure on myself by creating a dedicated YouTube vlog channel that I intended to update weekly and the quality of my blog posts seems to have suffered as a result.

I’m finding it really hard to work full-time and help look after two kids during school holidays while updating two blogs and a YouTube channel every week!

Accordingly, I’ll be updating this blog fortnightly until further notice (but still on Mondays). There won’t be a season 2 of the motorcycle vlog for at least a couple of weeks, maybe longer.

If you’d like to see more videos from me, check out my main YouTube channel at https://www.youtube.com/user/techheadfred. Updates won’t be as frequent but I’ll put up a bike video when I can.

Emergency Refueling And Trying Plastic Welding

This week, I ran out of fuel just before payday so I tipped some fuel from Rosie’s tank into a fuel can to refuel Sylvie. I also tried out my plastic welding kit for the first time.

I captured all the action on video – here’s the vlog:

The refueling comprised getting fuel out of Rosie’s tank into a fuel can, which proved harder than expected.

I eventually just poured the fuel out of the top of the tank.


I refueled Sylvie from the fuel can and promptly hit reserver again on the next day’s commute.

I filled up the fuel can again the next time I took my car out so I could get to work again without needing to completely fill the tank before the Christmas/New Year break.

I decided to try out my plastic welding kit on one of Erica’s side panels, as I hadn’t used it yet. It turned out pretty well for a first attempt.

I also found out that the clutch switch only stopped working again during the heavy rain we had last week and worked fine again once it had dried out, so replacing it is no longer quite as urgent.

That’s all for this week’s update – I’ll see what I can fit in over the next week. In the meantime, Merry Christmas to those who celebrate it, and Happy New Year to all!


Stopping Sylvie Stalling And Securing Shrouds – Fixing CBF250 Clutch Lever Detection

This week, I finally had time to spend on working out why Sylvie’s clutch lever switch hadn’t been working and secured the left front tank shroud fairing.

Here’s a video of the process:

I started by checking the switch to see if it was sticking.

Next I removed the lever and checked the swtich .

I then removed the switch and cleaned it with elctrical contact cleaner.

After a fair bit of testing, I found the issue was caused by the lever not allowing the switch to fully extend.

I put the lever in my trusty bench vice and used a trinagular file to put a small groove in the lever to allow the clutch switch to extend fully when the clutch lever is engaged.

Testing was a success, so I moved on to finding a replacement for a missing bolt for the the left side tank shround fairing.

That’s all for this week’s update

Apologies for the quality of some of the photos, I wasn’t aware that the GoPro had a terrible angle and didn’t take any other photos at the time. I’ll see what I can come up with for next week’s update and will try to remember to get more still photos just in case!



Re-covering Sylvie’s Seat Again – Video Edition!

This week, I finally got onto re-covering Sylvie’s seat.

Here’s a video of the process

First, I sewed the pieces of non-slip matting together.

Next, I removed the old cover.

Then I started stapling on the new cover.

Once I reached the front of the seat, I cut a triangular flap to avoid tearing the seat cover down the middle like I did last time I recovered the seat!

I trimmed the edges and gave the border a layer of duct tape.

I gave the seat cover a coat of waterproofing spray.

Finally, I replaced the seat.

Here it is after riding the bike today.

That’s all for this week’s update. I’ll see what I have time for next week!


Answering A Reader Question – CB250RS Control Cable Routing

This week, I had a question on cable routing from a reader, so I spent a bit of time looking at Scarlet and tried to answer it in this week’s video.


Of course, to trace the cables I had to take off the seat and side panels.

The cables cross over behind the instrument cluster.

After lifting up the tank, I confirmed that most of the routing happens underneath the tank and along the frame.

The choke cable goes under a clip on the engine frame.

The throttle cables go through a guide under the tank, then through a section of the frame and connect to the carburetor.

Here’s a picture from the service manual that might help too.

I also looked sadly at my peg board and the mess on the bench. I’ve decided to make a new tool wall solution, but I’ll most likely over that on my woodworking blog.

That’s all for this week. I hope that answered your questions, Nick!

Inflating, Gluing, Sketching And Shielding

This week I got a new mic for my GoPro!

I also finally made a start on re-covering Sylvie’s seat.

I’ve recorded another video this week, should you care to watch it:

I cleaned up a bit first, then put Scarlet on the centre stand and brought out my trusty second-hand air compressor to inflate her rear tyre.

My tripod mount for the GoPro broke, so I repaired it with some 5-minute epoxy.

I measured up the old seat cover for Sylvie.

I used a chalk marker to make a rough outline of the original seat cover.

I realised that this wouldn’t be big enough, and marked around the original line.

Having learned from previous experience, I measured the final size against the existing seat before cutting out the final shape.

I decided to sew the two pieces of non-slip matting together before measuring and cutting the final shape, so the seat cover is on hold again for now.

While the audio quality on the external mic was reasonable without WiFi on, there is unfortunately a common issue with GoPro Hero cameras where enabling WiFi causes horrible audio interference when using an external microphone. This is somewhat problematic, given that remote control for early GoPro cameras is via WiFi only.

I decided to disassemble the mic and check if it had any shielding. It didn’t, of course!

I tried applying aluminium tape to the insides of the external mic to shield it before reassembling it, but it made no difference.

I even made some progress on getting the sockets back in their places in the large set too!

That’s all for this week. While I made some progress on the minor tasks on the bikes this week, there’s still a lot more to work on!