DB gets a 2 Smoke!

[marcm]

When I suggested getting steering bearingsout with that method couple of years back to someone they looked at me as if I had 2 heads.....about 3 minutes later they were out..they maybe thought I was only partially stupid rather than completly daft..

[Dirtybrit]

Last few plastic bits off, airbox and crap deflector.
Mono Shock.

Cleaned up the airbox

Forks stripped and ready for new fork seals.


NewFork seals,Swing arm bearings,headstock bearings etc. On the left are the teflon bushings I made so I could ride in October. In the future I will go this way, needle rollers are expensive, fragile and in need of a lot of maintenance, especially if you use a power washer.


Chain guide is worn and brittle, so I will make a new one from some UHMW.




Rear brake pedal is worn, I will fit an "Oilite " bushing as this is hard to get at to lube as it is behind the footresrt.


Took the frame down to the sandblasters, and cleaned up the swing arm and chain guide pieces.


I sent all my bolts to be Cad plated, replace a lot of them with stainless, but the foot rest bolts where screwed and I could not buy replacements, so I made some new ones from some metric bolts.

Here is one of the footrest bolts.

I turned the head down to the same size as the flange on the original.

Milled on the Hex, 14mm.

Then faced and undercut the head, and had them plated.
The front Tyre was cracked with old age, so whilst looking on Kijiji Classifieds I saw a TTR 250 wheel for sale with a decent Tyre. Went to Boats.net and cross referenced the part, the wheel is the same. So I went and bought it. $20, good tyre rim,hub and brake shoes.....great buy!

Old Tyre.

Purchased tyre.

Exhaust is totally screwed, doesn't fit right, loads of cracks and leaks oil.

So I have ordered a new DG Pipe with Muffler from the States.

[marcm]

Bloody hell....that exhausts a bit special..ha ha..
The chain slider and guide block are still available from yamaha for the 250/465 and not too expensive,I've bought a few and used them reversed on the 125,which are no longer available.
If your going to do something with the original shock all balls do a seal head for them,and used a ktm 85 piston and piston ring in them on one that the piston ring was absolutely shagged out,I had to make up a shim stack for it,but it works well.
I will see if I can find some pics of it.

[Dirtybrit]

[quote="marcm"]Bloody hell....that exhausts a bit special..ha ha..
The chain slider and guide block are still available from yamaha for the 250/465 and not too expensive,I've bought a few and used them reversed on the 125,which are no longer available.
Things I can make myself I try and do to keep down costs.
If your going to do something with the original shock all balls do a seal head for them,and used a ktm 85 piston and piston ring in them on one that the piston ring was absolutely shagged out,I had to make up a shim stack for it,but it works well.
I will see if I can find some pics of it.
That would be great, the shock isn't too bad at the moment but I am pretty sure once my fat arse has been on it a few times it will be a little tired.

[Dirtybrit]

Painted the frame and swingarm.


I have started to re-assemble my bike but will need to take some more pics.

[marcm]

The shocks are usualy desperately overdue a bit of love,the oil is ususaly like a grey aluminium flavour soup.
I've don a few now,one I went with the ktm 85 piston in,others I just replaced seal head,cleaned,new oil and regassed and have worked fine.they do suffer a bit with the shock body wearing but there's not much can be done about that.
The 125 h I have I've just to another shock built for it,here's a picture...hopefully not upside down for the Australian market..ha.i will get them on the case when I'm back from my little jolly,to build me a tenere shock before Jo Jos rally in sept.

[Mezo]

The shocks are usualy desperately overdue a bit of love,the oil is ususaly like a grey aluminium flavour soup.
I've don a few now,one I went with the ktm 85 piston in,others I just replaced seal head,cleaned,new oil and regassed and have worked fine.they do suffer a bit with the shock body wearing but there's not much can be done about that.
The 125 h I have I've just to another shock built for it,here's a picture...hopefully not upside down for the Australian market..ha.i will get them on the case when I'm back from my little jolly,to build me a tenere shock before Jo Jos rally in sept.

Marc, sort your images out please buddy.

If everyone else takes the time to post an image the right way up then so should you, its as easy as wiping your arsehole, (pull paper, tear paper, fold paper, wipe).
Im asking you real, real nice now, ive hinted several times & even told you how to do it, please if your going to post images on another guys thread at least have the courtesy to post them the right way up, he made the effort & so should you.

Mezo.

[marcm]

Couldn't understand why some came out correct way up and one were upside down,when hadn't done anything different when attaching...then I realised the ones I had taken with a normal camera would appear correct way up,whilst some taken with I pad ,depending which way up it was,would appear upside down......dohhhh.....
Bloody simple realy but took a bit to realise.

[Dirtybrit]

Cleaned up the triple clamps, stripped the paint off and used a brass wire brush, worked a treat.
Fork gaiters are a little short, but may be a good fault as it willbe easier to lift to clean around the seal area.

New chain guide fitted.

Stripped the protective covering from the stator wires and re-covered, then used some plastic cable armour.

I made a new bronze sleeve for my brake pedal, and a new sleeve where the brake rod fits.

Then drilled the end for a tie wire to try and stop the pedal getting caught and bent., then fitted the pedal.