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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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!

A Chain And Sprockets For Sylvie

I got another parcel last week.

 

The new chain and sprockets arrived, with a catalogue from the seller’s company.

After checking my chain breaking tool, I realised it had seen better days.

The 520 pitch pin was burred and bent from the last chain I riveted and the spring I’d replaced the original with hadn’t fared well.

I de-burred the pin with my rotary tool.

After checking the pin was straight, I found a new spring.

I reassembled the chain breaker and prepared to remove the chain.

 

After locating the master link, I discovered that the old chain had a clip link, so the chain breaker wasn’t needed to remove it!

After removing the clip, I found I couldn’t pry the link out.

Moving the chain to a different position and WD-40 didn’t help.

So it was off with the wheel and there was room to move the chain a bit more freely.

A bit of brute force and the master link was finally freed up!

The old sprocket was next to go.

The new sprocket went onto the wheel.

Back on went the wheel.

 

With the rear wheel back on, the front sprocket cover was next to come off.

The front sprocket had definitely seen better days.

The new sprocket wasn’t going on the spindle without a good clean first!

Once the oil residue was cleaned off, the new sprocket went on.

I got a shot of the new chain with the old for contrast, then fitted the new chain.

The rivet link was easier to fit with the ends of the chain on the sprocket.

The o-rings were lined up and the outer plate put in place.

Then came the process of riveting the new chain. First up, I moved the master link to the bottom of the chain loop and pressed the plates together with the chain tool’s pressure plate.

I ended up switching between several different configurations to get the master link riveted.

FInally I managed to get a decent rivet on the chain without over-flattening the ends of the pins.

I cleaned up the rust and oil from the front chain cover.

The mounting bracket got a good clean too.

The cover went back on and I cleaned up the outside.

Here’s the new chain with the tension adjusted and rear wheel tightened .

Sylvie’s list got an update – I’ll revisit this in the next post.

My stepdaughter had been helping me clean up, so I got her to stand still long enough for a couple of quick post-cleanup shots. Note the oily hands!

I got a lot done this week, so will cover more in the next update.

CB250RS Parts Transplant – Sprockets, Chain, Side Panels, Mudguard And A Fuel Line

This week, I started with removing the rear wheel from the donor bike and salvaging the sprocket from it.

The sprocket and the wheel it came from…

 

And the sprocket after cleaning up with degreaser.

Next was the rear wheel from the “recipient” bike

  

This sprocket looked a lot worse for wear.

 

Almost like a saw blade compared to the donor one!

One of the bolts from this wheel had a 13 mm nut on it. I cleaned all 12 mounting bolts and nuts up with some degreaser and picked the best-looking ones

While the wheel isn’t in the best shape, I figured I can put a new tyre and new sprocket on it ready for when the bike needs a new chain. I put the better sprocket on the wheel as it had the better tyre before taking a short break for lunch.

After lunch, I compared my three front sprockets. I opted to use the right-most one as it had the least wear.

I cleaned up the primary drive shaft before fitting the sprocket.

The sprocket and the locking plate in place, fixed in place with the mounting bolts.

I opted to re-use the spare chain for now, after a liberal coating of “rust buster” spray.

Adjusted the chain tension, tightened the axle nut and fitted a split pin.

I popped the side panels in place and re-fitted the front mudguard.

 

I removed the front brake caliper from the “donor” bike and placed it in my bench vice to have another crack at loosening the stiff screw on the rear cover.

It chose not to cooperate, so I brought in the heavies – a small sledgehammer and traditional impact driver of the style from the days before they were all motorised. The recalcitrant screw soon saw the error of its ways!

Getting back to the chain, I realised the rear chain guard was a bit warped, so I retrieved the one from the “donor” bike and gave it a once-over with Inox.

Fitted and looking good!

The lower front chain guard was next. I fitted the plastic one too but I must have been getting tired by this stage, as I seem to have forgotten to take a photo of that step!

The helmet holder that matches the ignition, fuel and steering locks went on next, but was only fitted loosely as I’ll probably switch all the locks with Scarlet’s later.

Finally, I cut a fresh length of fuel hose to replace the piece that had been broken off prior to the parts transplant.

I haven’t started the bike again yet, I’m saving that for next week!