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!

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Khaleesi’s Rear Wheel Replaced And New Chain Fitted

This week, I replaced Khaleesi’s rear wheel now that her owner has organised a thinner profile rear tyre.

The first step was replacing the sprocket carrier with the new sprocket on it

I was trying to prevent the disc still from scraping on the brake mount but hadn’t taken enough photos at the right steps of wheel removal, so I wasn’t entirely sure how the spacers and washers had been fitted previously.

I decided to try the spacer and its matching washer together at first.

I fitted them on the inside of the brake mount

I applied some fresh grease to the axle

The rear wheel was originally from a KR1S, so I had some trouble fitting the spacers and washers in the right order.

After swapping the spacers and washers around quite a few times, I got to a point where I was satisfied that the disc was scraping as little as was possible on the brake mount and moved on to the chain.

I removed the clip master link and put it aside.

I was having a lot of trouble getting the chain onto the front sprocket, as it seemed to be getting wedged against the engine. I realised this was because I had mounted it with the flat side toward the engine! After removing it and flipping it over, I no longer had the problem and the chain fit nicely.

I measured the length the chain needed reducing by fitting it without connecting the ends and moving the chain tensioners to the lowest point.

At first it seemed to need 13 links removed. As motorcycle chain links are in pairs, they can’t easily be shortened by single links.

I pushed the rear wheel hub as far forward as it would go and found that the 120-link chain needed 7 pairs of links cut out, for a total reduction of 14 links.

With all the trouble I had replacing the rear wheel, I took it off again just to check there was a bearing on the brake disc side. There was, so I think the KR1S spacer missing from the axle might be needed to fit it properly.

I removed the extra links rom the chain with my chain breaking tool after grinding the end of the pins with a carbide wheel on my rotary tool.

I lined up the chain on the rear sprocket and fitted the master link and o-rings.

I put the cover plate on, then clamped it with my chain tool.

With the slots on the pins clear of of the cover plate, I fitted the clip with the split end at the bottom so as to be at the opposite end of the clip to the direction of travel.

I adjusted the chain tensioners and fitted a split pin through the castle nut and the hole in the axle.

I bent the ends of the split pin back around the castle nut.

I had some spare rubber glue, so I glued on the loose LED strip indicator.

I found that Khaleesi already had a connector cabled to the battery that fitted my trickle charger, so I sprayed it with some electrical contact cleaner and hooked up the trickle charger.

That’s all for this week – hopefully I’ll finish the remaining work on Khaleesi in time for next week’s update!

Khaleesi’s Rear Wheel Comes Off For A New Tyre And Sprocket

This week, I took off Khaleesi’s rear wheel so her owner could get a thinner profile rear tyre fitted in order to leave some clearance for the chain.

The rear wheel was originally from a KR1S, so it had some spacers and washers added.

The first step was removing the split pin from the axle.

 

This was followed by the castle nut.

Then I removed the spacer and right chain tensioner.

 

Out came the axle and the wheel was off.

 

There’s some damage inside the brake caliper mount. The owner told me it was from when one of the screws holding on the rear brake disc wasn’t tightened enough.

The wheel itself seemed to be in good condition.

With the wheel off, I removed the sprocket mounting plate.

I left the sprocket mounting plate with the axle while I inspected the rest of the wheel.

There were some scrape marks on the brake disc mounting plate and the rubber shock damper for the sprocket mount had seen better days.

I compared the new sprocket with the old one to make sure the mount points were the same before opening the packet. the size difference is due to Khaleesi’s owner deciding to change the gearing for greater acceleration on take-off.

I put the sprocket mount in my bench vice to hold it while I undid the mounting screws

The old sprocket isn’t really worn, so it’ll be kept as a spare. There’s a considerable size difference between the sprockets due to the new sprocket having 40 teeth where the original one has 45.

 

I fitted the new sprocket to the mounting plate and  put it back on the wheel.

 

Khaleesi’s owner then picked up the wheel so he could get the tyre replaced. The spare tyre he already had was for a 17″ rim rather than an 18″ one, so it looks like it’ll be a little while before the rear wheel goes back on.

That’s all for this week – hopefully I’ll find some brake pads for Sylvie in my CBF250 spares box or I’ll need to order some for express delivery soon!

Progress On Khaleesi’s Front Sprocket At Last!

This week, I got Khaleesi’s old chain from her owner so I could temporarily fit it and hopefully get the front sprocket off.

I lined up the chain on the rear sprocket so I could temporarily fit a spare 520 master link.

I fitted a clip-style master link without the clip just to hold the chain in place but forgot to take photos of that step. After a lot of swearing while putting most of my weight on the rear brake while trying to use a breaker bar on the opposite side of the bike, I decided to  liberally apply WD40, set my large torque wrench to the specified torque setting and give it one last try. To my surprise, it worked!

With the nut finally loosened, I removed the chain again.

The nut was next, followed by the retaining washer and the sprocker itself.

I put the parts aside until I was ready to fit the new sprocket.

With the sprocket removed, I set about fitting the replacement external shifter cover.

I then replaced the clutch lever.

Comparing the old sprocket with the new one, there was a world of difference in terms of tooth wear. Also noticeable is the difference in size, as the new sprocket is one tooth smaller.

I fitted the new sprocket and finally added the small plate on the bottom left of it .

I still need to check under the engine and make sure the crack doesn’t appear likely to be causing any other issues before filling it with some J B Weld.

After that I’ll need to remove the rear wheel, fit the new sprocket to it (or the original wheel if the chain doesn’t have enough clearance form the tyre), put the new chain on torque the front sprocket nut completely.

I’l also connect a charger to the battery and top up the oil if I have any suitable oil before she goes back to her owner.

That’s all for this week, hopefully I’ll have most of this finished and can focus on my own bikes again after next week!

Khaleesi’s Sprocket Refuses To Budge And Sylvie Gets A New Footpeg

This week, I attempted to get Khaleesi’s front sprocket off with an old o-ring chain between the sprockets. I couldn’t fit the chain fully, as it was a little shorter than the length needed.

I had discussed my suspicion that the o-ring chain wasn’t likely to fit with Khaleesi’s owner and we’d decided against opening the sealed bag for the replacement chain in case it turned out the rear tyre was too wide. This turned out to be a wise choice, as there was absolutely no clearance between the old o-ring chain and the tyre.

I had no luck whatsoever with getting the front sprocket off, even with the old chain on the sprockets and the rear brake applied as hard as I could manage. As I don’t own an impact wrench and I’m not sure about the extent of the damage indicated by the cracked outer side of the bolt hole for the left side engine cover I discovered last week, I’ve advised her owner that he’s better off taking her to a qualified motorcycle mechanic.

Sylvie’s rear footpeg was looking a bit bare, so I had been looking forward to receiving the replacement parts for it.

The parts arrived, so I unpacked them ready to fit on the footpeg.

I didn’t realise when I ordered them that I’d  missed the plate at the end closest to the bike. The pillion pegs don’t get much use at the moment anyway, so I’ll order one with my next parts order for her.

With the new rubber cover fitted, the footpeg should at least stay in the folded position a little better!

That’s all I had time for this week. It’s my baby daughter’s first birthday next week, so I may not have free time for bike work. If that turns out to be the case, I’ll see if I can write a post about the work I did on my compressor recently that I’d intended to cover in a bonus post I forgot to write.

 

 

Swapping A Footpeg And Work On Khaleesi Continues

Since the replacement parts for Sylvie’s footpeg hadn’t arrived and I needed to keep riding Sylvie, I checked the pillion footpeg on the same side and found the parts were all the same. I decided to swap them over, so off they came!

I fitted the parts to the front footpeg and folded the rear one up and out of the way again. I’ll fit the new parts to the pillion peg when they arrive.

Khaleesi’s owner brought over the spare parts I’d been waiting for, so I unpacked the rag from the external shift mechanism and inspected the area where the replacement cover needs to go.

At first glance, everything looked ok.

I compared the old parts with their replacements.

On closer inspection, it looked like there was some minor damage to the engine casing I hadn’t previously noticed, but not enough for concern at this stage. I’ll make sure I let the owner know and re-check the bottom of the engine for evidence of oil leaks.

I started fitting the parts. I had put the new gasket in place before I realised that I needed to remove the front sprocket before the replacement cover place will go on.

This turned out to be somewhat more difficult than I’d expected as the engine turns over when I tried to unscrew the mounting nut, so I took a break for the evening and will consult the manual before giving it another go.

I will be fitting a new chain and sprockets on Khaleesi too – hopefully I’ll have an update on that next week!

If my replacement footpeg parts and bearing kit for Sylvie arrive next week, I may have a few busy weeks ahead…

Organising The Pegboard And Starting On Khaleesi

This week, I continued organising the shed so I could get to my spanners and made another timelapse video in the process.

Here’s the shed from outside before I started.

A better view of the organised pegboard.

I found a few stray tools that don’t belong on the pegboard – some JIS screwdrivers that belong in the toolbox and a cheap set of spanners I don’t use on vehicles due to poor quality.

This was the mess on the floor in front of the bikes.

I had left a space for this spanner on the pegboard, as I knew it was somewhere nearby!

Much better!

Sockets in the box of bolts? This is what I end up doing when it starts raining unexpectedly!

This bolt had escaped the box altogether!

Another socket out of place.

With the wayward sockets out of the bolt box I finally was able to close it again.

The stray socket was reunited with is siblings.

More random bits and pieces on the floor.

The bolt box was relocated to the bench without losing the rest of its contents and the side-cutters and sockets left on top of it until they find a more permanent place.

The inside of the shed was slightly more easy to get to again at last!

I even looked a little less cluttered from outside compared to when I started!

With the shed more organised, I started looking more closely at the damage on Khaleesi.

The plates below the front sprocket came off first.

First was a single JIS screw that needed my large JIS driver to remove.

The other mounting bolts were 8mm.

Once the plates were removed, I disconnected the Neutral switch lead connector and the 8mm mounting bolts.

With the bolts removed, the larger part of the cover came straight off.

The part that had broken off was held on by a 10mm nut.

The nut wasn’t all that was holding it in place though. The oil seal around the selector shaft was badly bent out of shape and unusable.

With the oil seal out, it still wouldn’t move!

Some gentle persuasion with a ball peen hammer and a small pry bar soon took care of that.

I don’t own a MIG or TIG welder and I’m not very skilled with my arc/inverter stick welder yet. I also don’t have any aluminium arc welding rods, so I didn’t attempt to weld these aluminium alloy parts back together!

Fortunately, it didn’t look like there was any internal damage other than to the gasket.

I put all the parts and tools aside on a clean scrap of cardboard in front of the bike lift so they are out of the way until the new cover goes on.

Finally, I covered up the remainder of the external shift mechanism with a shop rag.

I’m waiting on a replacement cover, sprocket and chain from Khaleesi’s owner before I can finish work on her, so that’s all for this week.

I’ll continue sorting the bike shed next week. Hopefully some of the parts for Sylvie I’m waiting on will arrive too!