Been a bit slack in undated this rebuild thread,
Time to do some work on the front of the engine. The previous owner mentioned that the timing chain had not been replaced in 140,000km (85,000 miles). An yes it does need changing. Even with the tensioner in place. I can pull the chain away from the bottom sprocket.
Still a few miles left in the guide.
Timing chain replaced and a few goodies added.
Big care package arrived from the UK
It is easy pulling bikes bikes apart. Time consuming putting things back together. Spent about 3 hours rebuilding the rear brake thingo.
Rims are back from the powder coaters.
A bit of a mock up to see how things are going.
Now to get part A) engine back into part B) frame.
Ok time to put the engine back in the frame. I normally have a rolling chassis before putting the engine in. This time, I thought, I would try re fitting the engine into a bare frame. A lot easier. Just jiggle the frame up and down to align the engine bolts.
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Before refitting the engine. I rebuilt the front forks as the fork seals where leaking. Thread tape on the top bolts. The fork sliders had rust and pitting on the tubes. After I rebuilt the forks. I refilled the tubes with fork oil and there is a pool of oil on the ground. What is going on here. New copper washers were used under the fork legs. Removed the bottom 10mm allen key an used new washers, an the same thing happening again. Oil every where, Turns out the little copper washer on the drain screw next to main bolt was the culprit.
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Slipped the gearbox back in.
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Had a lot headaches trying to line up the swing arm equally. The pivot pins where really tight and you could move the swing arm side to side. Half an hour of head scratching trying to think what is going on. Powder coat on the inside surface area of the pivot pins and not allowing the pins to go in smoothly,
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What else could go wrong today, Should call it a day. Then, I noticed the filler bolt on the drive shaft has stripped, bugger. Out with the thread tap to see if it would fix the problem. Nope.
Digging into my old box of BM bits. I found a plug, I had made years earlier with a courser thread. I give that a try and it will work for the time being.
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Must stop bidding for things on Ebay:lol3 Ended up with a new set of engine bars.
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Wheels on. Still a long way to go
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Amazing how long it can take to fix little things like the seat lock.
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Keeping a bit of the police bike heritage. I am legally allow to speed now.
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Fitting the racks,seat & mudguard.
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Tank on for a bit of a mock up.
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Now the confusion really starts in main wiring looms. The original wiring loom is part number 61111244098 and fairly wrecked and needs a fair bit of work to salvage.
Andy Gadget comes to rescue with a new main wiring loom for an RT part number 61111243522. This loom is suppose to fit my bike. But is completely different in the amount of plugs and colour wire plugs.
Both looms are suppose to fit an 81 R100RT
Old Wiring loom
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New wiring loom
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Time to crack on with the wiring. I am still on the hunt for some reasonably priced headlight holders. So for the time being I am using a modified RT fairing carrier.
Started off removing this bit of wiring loom connected to the headlight shell. Not on any wiring diagrams and it has to do with the lights and sirens of a police bike.
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Cleaned up the mess inside the headlight from this
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To this. I am going to remove the fuses inside the bucket to blade fuses. To easy accessible place out the headlight bucket.
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New left hand switch block fitted.
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New sub loom made for the neutral and oil pressure switch.
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Still a long way to go in cleaning out each connection of mud and dirt.
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Wiring in headlight cleaned up √
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New left hand switch block fitted √
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New EME alternator and electronic bean can fitted √
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New coils and Starter motor fitted √
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Every time you work on a bike. There are always one or two parts left over.:lol3
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A bit of a mock up to see where things are heading.
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Little bit of DIY. External fuses. Won't have to remove the S fairing to check/replace fuses.
If it is ok for a Ducati Mille
Gold line Brembos
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Something like...
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Bit of a fit up before splashing on some paint.
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Bacon and eggs...A day's work for a chicken, a lifetime commitment for a pig.
No return if the welder does not get them out.
Gold line Brembos
