Friday, September 19, 2014

Beginning the Reassebly

Because I know my engine won't be ready soon, I've started assembly of the roller.  The front end is all sorted and on, the seat is on, and the rear shocks and swing arm are on. Like I did with the front shocks, I rebuilt the rears.  Other than to adjust the rear swingarm once the engine is in, I won't have to touch any of that stuff again.




A metric thread file came in really handy for the neck threads and front axle threads.



The wheels are pretty much sorted, I just have to shim  the rear bearing stack a little bit.  I got some shims from Duane Asherman.

I may put the front wheel on this weekend, but before I put on the rear, I want to dig inside the final drive a bit and see what I see (hopefully nothing bad!)  That'll be the last major operation on the bike until I get the engine back.

I thought using the BMW grease fittings would be problematic, but it was super easy with a decent chainsaw greaser. For the front, I did use Duane's tip of wrapping a piece of rope around the left side to keep the grease in.

I also got a good deal on a used 20mm x 1.5 tap to clean out the threads on the frame for the rear swingarm pins.



I replaced both sets of swingarm bearings which should have been pretty straight forward, but as is usual for me, I spent far more time fixing screw-ups than actually progressing.  I somehow thought it would be a good idea to use the old race to set the new race in place in the rear swingarm.  It worked, but the old race got stuck in the swingarm too and it took me a good hour to get it back out without damaging the new race underneath! I also destroyed two seals trying to seat them in place.  I got some new ones (as well as a set of extras) from Hans at Hucky's Spares.  These went in with no problem, so I have to wonder if my first set (which came with the project) were too big.  I really like dealing with Hans, it's very old school since you order through email and he gives you a discount if you mail him a check.

Like I said, next up will be the final drive, then I can complete the roller.