The other ER5 restoration .

[fastbob]

Fiddly bits .

[Slowlycatchymonkey]

Wow.

I’ve really enjoyed this thread. Thanks [mention]fastbob[/mention] I couldn’t read it quick enough!

Such a nice job, it’s hard to believe how well some of those parts came up.

The blue body kit was a bargain.

I also found sourcing quality petrol resistant lacquer a nightmare. They just don’t do what they say on the tin with tons of reviews saying how they crack and peel easily ruining the finish.

In the end I found Spraymax 2K which was the only one anyone recommended for giving a smooth professional level finish that lasts. Apparently unless the lacquer is in two parts and mixed just before spraying it’s gonna be too soft and weak for using in a vehicle.

It also means you’ve got limited time to use the can once you’ve mixed it. It’s also expensive but very well reviewed.

Thought you might be interested for your (next) winter project

[fastbob]

With ER5's being notorious for pissing petrol , my main concern is that the paint I applied to the engine will be washed away before it has a chance to cure .The silver bits have been oven baked but unfortunately the crankcase wouldn't fit .

[Slowlycatchymonkey]

I suppose only time will tell.

Considering the quality of your work on the rest of the bike it would be cosmetically annoying but not something you couldn’t rectify. You obviously have a lot of elbow grease!

[learningtofly]

Must say I find your work inspiring Bob.

 

Ditto. Superb thread.

[fastbob]

I'm going to stick a battery in it and turn the key later on . So it'll either be all systems go or Shit ! What's on fire ?

[fastbob]

And it's all systems go ! To be honest , there's no reason why it shouldn't be ok but when the loom has been off there's always the possibility that something decides to go Snap Crackle Pop . So , jobs outstanding . Fit two carb kits , replace the shocks , chain and sprockets , fit the exhaust and have another go at the calliper because I'm not happy with the feel of the lever . Oh and I've bought a ZZR 1100 petrol tap which I'm going to modify to fit . The reason for this is that ER5's are notorious for dumping their fuel into the sump overnight because the fuel tap is of a poor design and it is bolted to the frame six inches below the tank and fed by pipes . Rather than being vacuum operated , the ZZR tap is manually operated and more importantly it has an OFF position .

[fastbob]

Let's see if this works .

[Six30]

Let's see if this works .

 

top job bob, how much has it cost you all in ?

[fastbob]

Let's see if this works .

 

top job bob, how much has it cost you all in ?

 

Off the top of my head , about £650 but I might be slightly in denial . I'll have to check my eBay purchases some day . Anyway , you can't put a price on satisfaction .

[fastbob]

My ZZR 1100 fuel tap is here . I've stripped it and given it a spruce up . Now to figure out how to fit it .

[fastbob]

Here we go . I used a bit of scrap carbon fibre number plate to knock up a bracket extension . It'll do the job for now .

[linuxrob]

You know Bob, that petrol tap looks rather good.

[fastbob]

You know Bob, that petrol tap looks rather good.

 

It might be in the way of the idle adjustment screw but that can be sorted . I've ordered a pair of carb rebuild kits that include jets , needles, gaskets and even floats and diaphragms all for the ridiculously low price of £8.07 . I haven't been disappointed yet by too good to be true Chinese stuff so let's hope this is no exception . https://www.ebay.co.uk/itm/383767415660

[linuxrob]

Now that's cheap

[skyrider]

hope the kit works ok

[fastbob]

Now that's cheap

 

Price of Fish and Chips . What's to lose ?

[skyrider]

yep worth a try

[TimR]

You know Bob, that petrol tap looks rather good.

 

It might be in the way of the idle adjustment screw but that can be sorted . I've ordered a pair of carb rebuild kits that include jets , needles, gaskets and even floats and diaphragms all for the ridiculously low price of £8.07 . I haven't been disappointed yet by too good to be true Chinese stuff so let's hope this is no exception . https://www.ebay.co.uk/itm/383767415660

 

See if something like this would replace idle screw as longer than er5 one

https://www.ebay.co.uk/itm/184403629640

[fastbob]

You know Bob, that petrol tap looks rather good.

 

It might be in the way of the idle adjustment screw but that can be sorted . I've ordered a pair of carb rebuild kits that include jets , needles, gaskets and even floats and diaphragms all for the ridiculously low price of £8.07 . I haven't been disappointed yet by too good to be true Chinese stuff so let's hope this is no exception . https://www.ebay.co.uk/itm/383767415660

 

See if something like this would replace idle screw as longer than er5 one

https://www.ebay.co.uk/itm/184403629640

 

Yes , I've looked at those but I've also looked at putting it on the other side . It's not like you use it every day after all .

[fastbob]

A little bit of custom art work !

[fastbob]

I'm ok using Rattle Cans but I can't seem to find a suitable Clear Coat that is petrol resistant .

 

C'mon bob it's easy..

https://www.halfords.com/motoring/paints-and-body-repair/specialist-and-decorative-paints/halfords-petrol-resistant-lacquer-300ml-768697.html

Also, just because I'm posting, I wouldn't bother taking the barrels off. It picks up well from idle, the rattles go away, you don't seem to be choking on smoke.. There can't be much wrong with that!

[fastbob]

You know Bob, that petrol tap looks rather good.

 

It might be in the way of the idle adjustment screw but that can be sorted . I've ordered a pair of carb rebuild kits that include jets , needles, gaskets and even floats and diaphragms all for the ridiculously low price of £8.07 . I haven't been disappointed yet by too good to be true Chinese stuff so let's hope this is no exception . https://www.ebay.co.uk/itm/383767415660

 

Well this item has arrived and I'm astonished . Every piece of it is a true replica of the original . The bowl gaskets are a perfect fit , the floats are indistinguishable from the originals as are the needles . I only have one criticism and that's that the pilot and main jets are not marked with a size . So once again the Chinese have delivered the goods . By the way , the only bits I actually need are the gaskets and needles but even then I've still saved money .

[fastbob]

That's the exhaust refitted . It had a few nasty scratches so I went through the spectrum of Wet and Dry Paper ending in 2500 grit which , incidentally , is better than any paste that comes in a tube . I painted the pipework with Wilko barbecue paint and then ran a heat gun on maximum setting through the down tubes to cure it . I would have liked to have put a nasty little slip-on can on it but there's nothing doing on eBay as yet . 

Edited November 21, 2020 by fastbob

[fastbob]

Oh , and remember to check your nuts !