Project 53 KL 04

[Green Goblin]

What a chuffing day I have had today with these bikes. I have been focusing on 53KL02 today as the frame on 52KL04 is a bit suspect. The bikes have fought me all the way today and its not like I haven't done the jobs before. All I wanted to do was swap the forks over, fit the front wheel, split the chain and fit it,a few other little bits and last but by no means least bleed the front bloody brake. I spent over 2 hours trying to bleed it and then decided enough was enough for the day. I went to drag the bike outside to start it and it got caught on every thing possible, it was as if it didn't want to go out in the cold. When I did get the bike outside it wouldn't start and leaked petrol all over the engine from the carb. So after a crap 6 hour session on the bike I decided to sweep up and clean the gallon of brake fluid up from off the floor. After the clean up I went back to the bike tried to start her and away she went, running at last. I fitted a clutch lever to the bike today so I was able to try the clutch and gearbox for the first time, so clutch in first gear and nothing, no 2nd, 3rd, 4th or 5th, luckily the chain wasn't on the front sprocket so that was easily fixed. After fitting the chain I rode the bike around the garden and all was well. Back in the garage sweeping up I fount a ball bearing and instantly new where it had come from. So straight away whipped the bleed nipple out and popped it in the brake caliper. only to then realise there was already one stuck to the bleed nipple. So like I said before not a brilliant day. Tomorrow hopefully if time permitting and swmbo I'll remove the half center stand that is fitted and fit the one from 53KL04. Al being well my mate will call around and give a hand with the front brake, I think we are going to try and get the caliper higher than the master cylinder to encourage the air to float up and away.

Rant over, no one else to rant to as partner not bothered about crappy old motorbikes.

[MT Pocket]

Hiya,
The fork spacers were put in dependant on how heavy you are, what event you were going to do and how much sag was already on the springs - someone here should know the correct start length, I just used to remove all 'weight off' travel. We also used to use the engine oil in the forks.

That rear silencer is like one of mine but it should be close to the rubber heat pad - that looks bent to me, more likely to be pipe than frame.

If you can syringe brake fluid in from the bottom with the pistons retracted this may help. In total desperation, lean the bike over (as to get a straight line as poss on the lines) and keep an elastic band on the lever overnight. Release it slowly in the morning, 'tickling' the lever. Sounds kinky but it works.

Good luck

[Green Goblin]

Thanks for your input green frog. I've had another go this morning, A mate came to help. We lifted the caliper up higher then the master cylinder and wedged a spanner in the pads to stop then trying to move. We got clear fluid coming out when bleeding but still no pressure on the lever so we have tied the lever back and will see what happens.

Stewart

[bth2bth2]

Thanks for your input green frog. I've had another go this morning, A mate came to help. We lifted the caliper up higher then the master cylinder and wedged a spanner in the pads to stop then trying to move. We got clear fluid coming out when bleeding but still no pressure on the lever so we have tied the lever back and will see what happens.

Stewart

ive had this prob with my zrx when i changed the caliper seals. i just left the master cylinder lid off and lever tied back to the bar over night.sounds like you have an air lock in there somewhere.
brian

[Green Goblin]

Hiya,
Release it slowly in the morning, 'tickling' the lever. Sounds kinky but it works.

Good luck

please excuse my ignorance what do you mean by tickling the lever?

Stewart