XT600E 1991 Ex Aust Army Project

[Danjet600]

finally got the donk out

[Danjet600]

swingarm
stripped the swing arm today and took it down to be powdercoated
first problem undone the bolt that go's through the linkage and


hardly put any pressure on it and it let go
looks like it was only just holding on
second prob
little bolt that holds a small bracket that supports the rear brake line wouldn't undo just spun around so had to cut it

so out with the welder

filled the hole and drilled new hole welded nut on top not the neatest job
but once the powdercoat go's on should hide it

getting stuck into cleaning all the bits

the swing arm bushes and bearings will need to be replaced, i hope all these bits come in the kit
you can see where the needle rollers have worn into these sleaves

this bearing is seized (arrow) , the hole in the center seems to have a rubberised coating in it but it is starting to flake off looks to be a sleave that can be pressed out and replaced

other bits cleaned up

[Danjet600]

got the sand blaster out this arvo and

after i had sand up me nose in me ears


snowing?????
started sand blasting around the welds on the frame that need repair, also will sand blast all the welds and check for cracks ect

underside of the offending brackets all cleaned up and ready for welding

cleaned all the welds back so i could check for cracks all looks good



this bracket needed some love

all straight now

[Danjet600]

swingarm back from the powder coaters

hid the rough welds here

gave the shock linkages a couple of coats a paint

i sandblasted/painted the spring/bracket for the side stand

hit a few more bits and pieces with primer and undercoat

[Danjet600]

sticker


mocked up the forks just to see how the wrinkle paint looks



still got some cleaning to do on the forks but really happy with the wrinkle paint
this nut gave me some grief had to go and buy a 27mm deep impact socket to get it undone and the rattle gun struggled

didn't look like it had ever been undone as the factory paint was still on the nut, there's a fair bit of crap in the filter

and once i got it out, i sent this stuff down to be sand blasted and the frame powder coated, the color is 1 or 2 shades lighter than the factory paint but it's the closest match they have

got the frame back


just waiting for some parts and it will be a roller in no time
shed time
spent a bit of time in the shed today, primed and undercoated a few bits

cleaned up the forks ready for some primer

while i was cleaning up i found this

looks like a small stress crack will have to get a new 1

[Danjet600]

some parts came!
head stock bearing came so made a start on the reasembly


love the contrast with the black wrinkle paint
well the weather in SE QLD has finally cleared up and i got out done a bit of sand blasting and painting

so i ended up painting the forks the same colour as the swingarm
i was thinking about doing them in the black wrinkle paint to hide some of the damage but then i couldn't put the yamaha stickers on the forks

pics don't show but there is a silver fleck in that paint

some other bits done in black hammer tone


more bits painted up

mock up
couldn't resist putting a few bits together to see how the colours are looking

[Danjet600]

full gasket kit arrived

budget job
got the rear wheel sand blasted ($20) and i etch primed it ready for painting

now the front wheel has been giving me dramas, the bolts that hold the disk on were all seized i've been spraying them with wd40 everyday for a week

so out came the cold chisel and hammer

every single one of the little buggers fought all the way
anyway i will be chasing some alloys down the track so a clean up and paint job for the rims for now
been looking at tires for awhile finally decided on some dunlop 605's
got new wheel bearings and heavy duty tubes


so i tried out the garbage bag tire fitting trick http://www.youtube.com/watch?v=P6sH8WRl6yI it works, i got a bit carried away with the talc , still had to use the levers on the last bit but next to no damage to the painted rim


front rim 2nd coat, the spokes are a bugger to paint you think they are all covered then look from a different angle and missed a bit

front tire fitted, new wheel bearings installed

pics dont show it but i polished the speedo drive and axle holder why you might ask cause i like shiny bits


a bit of wrinkle paint on the disk

and used some stainless bolts

[Danjet600]

more stickers

new ignition switch with 2 keys

dash on and new led blinkers


started sanding back the plastics to remove sun damage 1 side panel done

the plastics are pretty scratched up going to have to do something here
parts arrived today not the swing arm kit yet bugger

swingarm kit finally arrived won't be long and i have a roller again

as the gaiters i got with my bike are green i decided to order some of these

starting to get a bit carried away again
sand blasted some more bits

after etch primer and undercoat gave them a hit with the wrinkle paint looks normal when its wet



while these were drying i used 600 wet sand paper and sanded then polished the levers ,assembled ready to fit



got some more parts

fitted the rear swing arm today still had a few mods to make it all fit

had to bend this bracket to get a little clearance
also had to take to the shock with the die grinder


now i have room for the shock to move through it's arc, it's a bloody close fit the stress levels raised slightly while grinding away at the shock
i was missing the little guard that sits on the left side swing arm bearing so i hunted around and found the neck of a plastic water container is a close fit

so with some grinding, hack sawing and die grinding


rolla
got it back on the wheels


so i though a mock up was in order



possible problem......it's huge....... the seat height is now 930mm i'm wondering how much the weight of the motor ect will lower it?
i've already got the shock on it's lowest spring seat position and the pre load is as low as possible.
good news shock works really good has firmed the rear up and the rebound adjustment works

had a hour spare this arvo so i made a start on the wiring harness




so its a mess has lots of soldered joins some taped some not just have to get rid of all the army mods and put it back to standard

[Danjet600]

plastics
i've been thinking about what to do about my plastics the thought of preparing them for painting and buying the right primer/undercoat ect
so i bought 10sqft of matte black vinyl wrap
first some repairs, plastic welded a crack and sand all the rough bits



this is what i started with gave it a good scrub with warm soapy water

and then made a start

its surprisingly easy, apply a bit of heat from a hair dryer and you can pull out any creases and stretch it around corners

not too shabby for my first go

tools of the trade

you can still see some of the scratches through the vinyl but so far happy with the look of it

[Danjet600]

well thats it so far all up to date