Started the service work this weekend to get the bike up and running, work included:
Belts
Plugs
Air & Fuel filter
Fluid flush
New tires as it is still wearing the Hi Sports it was delivered with back in 1992!!,
First the air filter, as you can see it was pretty dirty:
Next up was the belts, I think the original owner rode the bike for only 2,000km from new then stored it, so the belts were original. No shocks in removing the belts, they looked as you would expect with a fair amount of surface corrosion on the tensioners.
They cleaned up fine with some scotchbrite
The only issue was that both tension adjuster locking nuts had seized on the shafts, so as you can see it took a couple of nuts locked on and an air impact driver to get them off.
Belt fitment and tensioning was pretty easy and all went back togther fine, fitted new plugs and all went well.
Next up was a brake and clutch flush, the fluid in the mastercylinders looked ok, but take a look at what I flushed out.
you can see the new fluid in the tube, but I have never seen fluid this bad in a system, as I mentioned earlier the bike only has 2,000km's so this is what 21 years of standing does to brake fluid!.
Last was the fuel filter and I was ready to go, replacement other than smelling of gas was simple with the tank cap removed for access.
So the bike looked ready to go, fitted a battery and.....nothing😡, this suprised me as the bike ran when I picked it up last year.
On checking there was something wong with the starter button as it didnt depress and return, stripped that and the spring behind the button had just compressed, stretched that and refitted it and still nothing. The main relay fuses were good but not clicking when I switched the ignition on, ignition lights on but nothing else. I must admit I am an electrical retard, so back to the basics, I checked the dash fuses and the only one blown was the rear light/hi beam, fitted a new one and this time at least the main relays were now clicking on switching the ignition on and it now turned over, but still no fuel pump. I have no idea how the headlight 15amp fuse also is linked to the full starter relays running, but it worked..sort of. So it will always carry a spare 15 amp fuse.
Back to the fuel pump. Cap off again I had a look inside the tank and as expected one of the fuel pump connections had come off, I must has dislodged it when I fitted the filter, on checking the connection was loose, so I bent them tight with pliers as I didnt want them working loose whilst riding.
With everything re-fitted it started straight up😉😉😉😉
Took it outside and gave it a full wash and degrease, finished today by polishing and refit the bodywork.
Hopefully tomorrow I will get all the bodywork on and give it a brief VERY GENTLE ride as it is still on the Hi Sports, I have a new set of Dunlops waiting to be fitted later this week.
Hopefully tomorrow I can share some finished pics.
