Made an arse of myself...
Task at hand for the weekend:
1 - change fork oil on the Pan,
2 - Mount the new satnav on the pan
3 - reassemble the carbs on the shadow with the new diaphragms.
You would think that 2 days would be more than enough to do the job.
Well... Not if you're me.
Friday evening
First spent 1hr trying to remove the cap from the forks. broke 3 17mm bolts and the thing wouldn't bulge.
"Need to get a 17mm key for this so I leave it for tomorrow (Sat)
Started with the satnav mount.
This seems an easy enough task.
Put the U bolt on the diy bar, pass the cable to the power connection
so 30min should be good. and I shouldn't need to remove the fairings.
First task.
Lost one of the nuts... twice
second time never saw it again
Thread on the U bolt is not metric so I can't bloody find anything in the garage to fit.
Passed the cable but because it goes under the tank and under the seat fixing I had to remove the fixing and elevate the tank, which is full, to pass the cable underneath.
Decided to stop the work as it couldn't go any worse and come back on sat.
While having dinner I remembered that I must ease the top bracket on the steering so the cap can come off... "you fecking w@nker"
Saturday - Only started working in the afternoon because spent the morning shopping.
Loosened the cap in 5min. (I know, what an idiot)
removed the forks one at the time,
spent 15min looking for my oil drain tab, an old 5lt oil container that I cut the side.
Used the cleaning bowl instead because I have no idea where the tab is.
Removed the allen screw on the bottom. This takes around 1/2hr because the allen key needs to be long and not round tip. so managed to ruin the bolt's head on the first fork.
tip: hit the bolt like if you were a baboon on crack a few times before trying to remove it. This scares the sh@t out of it and he will come out easily.
opened the fork and what a better thing to do than spread half of the dirty oil on the garage floor..
found the tab.
Did the same on second fork making sure all parts were well apart from the other fork's bits.
let them to drain.
While waiting I went back to the mount
Passed the cable from the front to under the seat. connected the cable to the power point. tried the satnav to see if the power was on. Nothing!
Checked the + cable and the power was on bt you can only connect a cable when you remove the isolation... So, removed the ground cable, took 10mm of isolation and put it back.
Then broke one of the bolts for the seat fixing.
Spent 1hr looking for the damn nut but still no luck. for sure will appear as soon as I get another one.
Then got the carbs for the shadow and the diaphragm rubber thingies.
So I got 2 sets, because they were cheap and I wasn't sure the size of the first ones. first set just the rubber, second set rubber with piston.
Because the bits were out already I just had to remove the rubber from the pistons, install the new ones and that should be it.
Now, keep in mind that I'm dealing with 3 sets of rubber bits. the old one (A), the new one (B) and the other new one with the piston (C).
The (A) come out after I broke the plastic bit that holds it in place from underneath. So a fix is needed, I found a O-ring that will do the trick just fine.
Fitted (B) but is showing to be too small on the outer diameter.
Tried (C) the piston is too small so I can only use the rubber. This seems to be too large on the inner diameter
Realised that (C) is in fact (A) and was loose because I almost rip it apart when removing it.
Put the whole thing to the side and went back to the forks.
The first fork would be drained by now so I started to clean it.
The casing was ready for wash so I just removed the damper, spread a load of oil on the floor again and on my boots.
You need to action the damper a lot of times to remove the oil.
Repeated for the second fork.
All cleaned and ready for assembly
Sunday
30 min looking for the nut and spanking the fairings trying to make it drop. no luck...
Started assembling the forks, made a new bolt from one I found in my parts box. I love that box.
Just make the thread all the way to the head of the bolt and it was done.
placed the fork vertical, followed instructions and filled the fork.
made a 62mm marker so I wouldn't fill it too much.
complete it and set aside to fit later.
same for second fork.
Lunch break
back to the mount...
Had to drill the broken bolt, and make a new thread for a M8 screw.
placed the cable on final location ready to finish.
looked 1hr for a replacement nut. Nothing.
tried to rethread another nut but I thread bit is metric so no good from there.
Mounted the forks into place. Need to make sure the space between the cap and the top of the steering is the same for both. For some reason the second went everywhere but the right position...
managed to get it right at 5th time.
dinner time and I can't be bothered with it anymore...
will carry on during the week.
And this ladies and gents, is how you don't do these tasks...
