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!

Sylvie Demands a Sleep-In, Her Bearings Arrive And I Suspect The Front Brake Pads

Just a short update this week, as I was celebrating my baby daughter’s first birthday over the weekend.

Last Monday Sylvie refused to start until I gave her a jumpstart from the car after not being ridden for a couple of days over the weekend. This wasn’t completely unexpected, as I’ve been using the heated grips a lot more now that the frosts have started and have a fairly short ride to and from work. I’m planning on fitting some wiring to allow a trickle charger to be connected in order to prevent this issue recurring in the dead of winter.

The replacement front wheel bearing kit for Sylvie arrived this week!

I was quite impressed with the kit.

While these looked like excellent aftermarket parts, I decided to take another look at the front wheel before fitting them as the noise seemed to be coming from the vicinity of the front brake caliper.

The pads seemed quite worn, so I decided to hold off on removing the front wheel until I have ordered some new brake pads and possibly a new brake disc. I’ll have to check the disc thickness just in case…

That’s all for this week. Next week I’ll most likely be making a weekend trip to Sydney to pick up some spare parts I’ve been offered for free if I can collect them!
Hopefully I’ll get some shed time in soon as well.

Covers Go On The Bikes, I Take Stock Of One Shed, And I Attempt To Build Another

It’s been a surprisingly busy week, yet still not one with much action on the bike front as I’m still waiting on parts for Sylvie.

We had a thunderstorm, so the bikes still in the yard have had their covers put back on until there’s room for them in the carport again.

My pegboard for the bike tools needs refilling, as I still haven’t got around to putting them up again since the shed was reorganised.

While this side of the shed is somewhat organised, there are still a lot of random bits and pieces that need a permanent home.

The shelves on the left are getting a bit out of control, so there’s another round of reshuffling that also needs doing…

There are two bikes to work on in the shed but I need to talk to the owner of one of them and agree on a figure for the work that needs doing on it, I need to clear a few things off the floor before there’s really any room to work, and the other bike needs some clear bench space to put the motor on!

With everything gong on, poor Sylvie has been parked on my front footpath for the last few days and is looking a bit sadder than normal about not being ridden all weekend, perhaps because I had an extra day off?

I’m still waiting on some new parts for her and need to order those front wheel bearings too!

The reason the carport has been cleared out is to make room to build another shed in there.

This shed was originally intended as an art space for my fiancée and is now destined be used as additional weatherproof storage for the clutter in the house and other sheds so we can sort it and get rid of some junk. I moved a few things around in it this evening so they are less exposed to the elements, as I’ll need a bit more time to finish this shed off than I thought!

Sylvie was at least able to be moved back under cover when I’d finished. The rubber grip matting I’ve used as an extra seat covering is starting to wear under the grippier parts of my motorcycle pants, so I’ll need to find a more permanent replacement seat cover soon too!

I’ll get stuck into the cleaning up this week, so if any parts for Sylvie arrive this week, I’ll most likely have another busy weekend ahead!

The Bikes Get Some Air And I Have Doubts About Sylvie’s Bearing

Just a quick update this week, as I’ve been busy clearing up the carport in order to assemble another shed in it for a workshop. This of course meant moving all the bikes out temporarily!

Rather than leave the bikes I’m not riding out on the front driveway, I moved them into the yard and made sure all their side stands were supported so they wouldn’t sink into the ground.

Sylvie was squeezed back into the available space in the carport, as she’s my primary mode of transport.

I’m still waiting for the other parts for Sylvie to arrive and the grinding noise from the front wheel hasn’t stopped, so I thought I might be able to use the bearings from the pare rear wheel. Unfortunately, they’re not the same Honda part number, so they’re unlikely to be the same size!

I’ll be ordering an aftermarket bearing bit that includes dust covers, as it’ll be half the price of the genuine ones.

That’s all for this week, hopefully the parts will arrive soon for Sylvie and I’ll be able to fit in a bit more bike time next week…

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.

Sylvie’s New Headlight And Bar Ends, A Then And Now Comparison, And A New Front Tyre At Last!

This week, I had parcels arrive with parts for Sylvie.

The first was a replacement headlight.

The second one was a set of bar end weights.

So these parts were of course installed this week.

I started with the bar ends. While the left one didn’t seem too bad, the right one had definitely seen better days.


Off they came. I put them with the replacements for comparison and to decide which two of the three better ones I would ultimately use.

I ended up using both replacement bar ends with one of the original screws (the two rightmost ones in the picture),

Looking pretty snazzy!

Next I moved on to the headlight. The original one was somewhat worse for wear, having developed a cloudy patch in the polycarbonate lens.

I removed only the headlight unit and put it beside the replacement for comparative purposes.

I noticed that while the replacement headlight did have a dented rim, the original was slightly dented in roughly the same place and also had a large scratch on the outside of the rim. I decided to straighten the replacement one as well as I could and just use it anyway.

I popped the replacement headlight into place and screwed it on with the screws that came with it.

Finally, I decided it was time to do a comparison between what Sylvie looked like when I got her almost a year ago and now, so I put her in the same place the original shots were taken and took photos from similar angles. Looking at them, it’s hard to believe it’s the same bike in some shots!

From the right side.

From the left side.

Front-on view.

Rider’s viewpoint.

Rear view (number plate in current shot obscured for privacy).


Closer front view.


I added and ticked off a few more things on Sylvie’s list.

Finally, I had a new front tyre fitted this morning, so I rode extremely carefully from the mechanic’s workshop to work!

Here’s the tyre just before being changed and after riding to work.

And of course the list has one more update.

Next week, I’ll either try the valve clearances or start work on the other bikes again!