Yet Another M900 Build - Page 45

PPuxley · 11-10-2021, 05:23 PM

This morning I finished installing the new Choke holder and then re-assembled the airbox, battery and everything else you have to strip to get to the choke.

After that I fired her up and went for a circuit of Pangbourne and Tidmarsh, which is about 4 miles. This morning this included a set of temporary lights , which when I stopped at them, I found the idle adjustment was way too high, Im guessing 2 or even 3000rpm. I also noticed that it was popping on closing the throttle.
This turned out to simply be overfuelling because the butterflies were set so high that excess fuel was still being delivered even with the throttle "shut".
I got home and adjusted the idle down - at least that isnt quite the PITA that adjusting the balance screw is.

I then took a run into Reading to see my mate Pete Sims who has a more or less production line of Zeds he restores. After a long chinwag, I returned home, now with the idle much better and no popping.

Theres still no fuel at the local Texaco, theyre still running out everyday, and with my new Low Fuel sender telling me I was ....Low, I thought that was enough for the day.

The only other thing I noticed was a very slight harshness or slight vibration when feathering the clutch to pull away in first, that I dont recall from before the rebuild....any pointers? I did have a look at the plates and they looked OK.

So I returned home after a coffee at Costas and gave the bike a good once over for anything amiss.

Turned out the cylinder oil return banjos were weaping slightly, so tightened them, but all else looked OK....well I had only done about 10 or 15miles!

I then spent the afternoon tidying up the wiring, zip tying and tucking it away from view behind the tank seat and carbon flashes.

So as the weather allows I will be doing ever increasing circuits of home.

Davy · 11-10-2021, 06:20 PM

She looks great patrick.

PPuxley · 12-10-2021, 08:28 AM

Some little stuff today. Labelling.
Ive trawled my "before" photos and videos but it looks like the labels were gone. Can anyone help with positioning the ZDM and E3 decals.
Im also making up the self adhesive rubbing strip pads. It looks like 4 layers of Hippo duct tape will do nicely
Finally Im having the seat lock label done at a local sign guy. There will be some available if anyone needs one.

350TSS · 12-10-2021, 08:30 AM

You have made a superb job of it - you should feel well deservedly pleased

PPuxley · 12-10-2021, 08:51 AM

Quote:

Originally Posted by 350TSS

You have made a superb job of it - you should feel well deservedly pleased

Thanks. Ive found it really enjoyable and Ive learnt a lot thanks to all you guys on here.

Luddite · 12-10-2021, 11:36 AM

leonlc had some ZDM and E3 decals made by classicmotorcycledecals2 on eBay so you could PM him for location details. (You might be able to work out the position of the ZDM sticker from the photo in his first post.) http://www.ukmonster.co.uk/monster/s...ad.php?t=58828

If you haven't already printed your seat sticker, they also do one of those too.

https://www.ebay.co.uk/itm/DUCATI-M9...-/164359095835

PPuxley · 12-10-2021, 02:32 PM

A bit more mileage today. Another 30 miles today to Ewelme to visit Tyrone at Riviera Autobody who did all the paintwork and lacquer on the bike and let the guys that worked on it take a look.
Then up the Chilterns to Stoke Row to fill up with 99 ethanol free from the independent garage there, followed by a coffee at The Black Horse in the woods at Checkendon, before dropping in to have a tea with Grubby who was wrestling with a front end crashed Harley on the lift.
Seems to be going OK with nothing dropping off or leaking. 🤞🤞

BLACK HORSE AT THE BLACK HORSE

PPuxley · 12-10-2021, 04:18 PM

Quote:

Originally Posted by Luddite

leonlc had some ZDM and E3 decals made by classicmotorcycledecals2 on eBay so you could PM him for location details. (You might be able to work out the position of the ZDM sticker from the photo in his first post.) http://www.ukmonster.co.uk/monster/s...ad.php?t=58828

If you haven't already printed your seat sticker, they also do one of those too.

https://www.ebay.co.uk/itm/DUCATI-M9...-/164359095835

Thanks for the info, Luddite

Jam911 · 12-10-2021, 04:59 PM

Gorgeous - Well done

PPuxley · 15-10-2021, 03:04 PM

Today I thought I'd wage war on sloppiness- the side stand and the gear change

VIDEO OF THE PROBLEM

Play on the side stand pivot has a couple of consequences.

Firstly it allows the return spring to pull the stand outwards especially in the up position and this can foul the gear pedal movement

Secondly it allows the bike to lean dangerously far over when in the down position
I used an 18x22x30 bronze bush from Henderson Bearings

I dont have a lathe or milling machine so I used a 21.5mm Blacksmith drill to open up for the bush. Because the drill wandered a little I didnt need to ream the hole further and the bush was a good tight push fit.

Not pretty but effective and quite adequate for a simple pivot.

The revised pivot bolt is made from some M12x1.25 fine thread with a plain washer welded to the head and a couple of flats so you can turn it. The reduced height head allows the return spring plate to pass over the pivot point and thereby remove the automatic spring back of the sidestand that leads to those unfortunate dropping the bike moments.
The consequent risk of moving off with the side stand down is mitgated by a lockout relay that cuts the ignition if the transmission is engaged with the stand down, but there are further lockout relays that allow the bike to be started with the side stand down, but out of gear.

I also ordered a couple of rod ends to get rid of the gearchange slop, its still not perfect because theres a little play in the pedal bush too

Darkness · 15-10-2021, 03:57 PM

Eek! Look at the state on that gear linkage tube!!

A previous owner of one of mine used an economy solution to the wear in the wishbone joints:

(They didn’t buy the new ones!)

PPuxley · 15-10-2021, 06:41 PM

Quote:

Originally Posted by Darkness

Eek! Look at the state on that gear linkage tube!!

Oh! You cut me, Mark

Darkness · 15-10-2021, 07:05 PM

That’s more what I expected from you Patrick!

Do you like the “adjustment” of the bronze bush with a hammer and nail?

PPuxley · 15-10-2021, 07:49 PM

Quote:

Originally Posted by Darkness

Do you like the “adjustment” of the bronze bush with a hammer and nail?

Oh Yes, spotted that.

utopia · 17-10-2021, 09:43 PM

Quote:

Originally Posted by PPuxley

I dont have a lathe or milling machine so I used a 21.5mm Blacksmith drill to open up for the bush. Because the drill wandered a little I didnt need to ream the hole further and the bush was a good tight push fit.

I did a bit of engineering many moons ago and I was taught that a normal drill, particularly a big 'un, will always wander and/or chatter when used to open up an existing hole.
Apparently the "proper" way to do it is to use a drill with three flutes rather than two.
These are called "core drills" and centralise/stabilise themselves somewhat along the lines of a three legged stool.
Not that anyone other than a specialist is likely to own such a drill, but its useful to be able to expect the standard version to perform badly and cut oversize, thus avoiding any resultant scrappage.
I'm glad it all worked out ok for you in the end.

11-10-2021, 05:23 PM	#661
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	This morning I finished installing the new Choke holder and then re-assembled the airbox, battery and everything else you have to strip to get to the choke. After that I fired her up and went for a circuit of Pangbourne and Tidmarsh, which is about 4 miles. This morning this included a set of temporary lights , which when I stopped at them, I found the idle adjustment was way too high, Im guessing 2 or even 3000rpm. I also noticed that it was popping on closing the throttle. This turned out to simply be overfuelling because the butterflies were set so high that excess fuel was still being delivered even with the throttle "shut". I got home and adjusted the idle down - at least that isnt quite the PITA that adjusting the balance screw is. I then took a run into Reading to see my mate Pete Sims who has a more or less production line of Zeds he restores. After a long chinwag, I returned home, now with the idle much better and no popping. Theres still no fuel at the local Texaco, theyre still running out everyday, and with my new Low Fuel sender telling me I was ....Low, I thought that was enough for the day. The only other thing I noticed was a very slight harshness or slight vibration when feathering the clutch to pull away in first, that I dont recall from before the rebuild....any pointers? I did have a look at the plates and they looked OK. So I returned home after a coffee at Costas and gave the bike a good once over for anything amiss. Turned out the cylinder oil return banjos were weaping slightly, so tightened them, but all else looked OK....well I had only done about 10 or 15miles! I then spent the afternoon tidying up the wiring, zip tying and tucking it away from view behind the tank seat and carbon flashes. So as the weather allows I will be doing ever increasing circuits of home. __________________ Golf-My favourite game. While my wife plays I'm in the workshop. Last edited by PPuxley; 11-10-2021 at 05:27 PM..

11-10-2021, 06:20 PM	#662
Davy Registered User Join Date: Aug 2007 Location: Derry Bike: M900 Posts: 358	She looks great patrick. __________________ 1994 M900 Black

12-10-2021, 08:28 AM	#663
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	Some little stuff today. Labelling. Ive trawled my "before" photos and videos but it looks like the labels were gone. Can anyone help with positioning the ZDM and E3 decals. Im also making up the self adhesive rubbing strip pads. It looks like 4 layers of Hippo duct tape will do nicely Finally Im having the seat lock label done at a local sign guy. There will be some available if anyone needs one. __________________ Golf-My favourite game. While my wife plays I'm in the workshop.

12-10-2021, 02:32 PM	#667
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	A bit more mileage today. Another 30 miles today to Ewelme to visit Tyrone at Riviera Autobody who did all the paintwork and lacquer on the bike and let the guys that worked on it take a look. Then up the Chilterns to Stoke Row to fill up with 99 ethanol free from the independent garage there, followed by a coffee at The Black Horse in the woods at Checkendon, before dropping in to have a tea with Grubby who was wrestling with a front end crashed Harley on the lift. Seems to be going OK with nothing dropping off or leaking. 🤞🤞 BLACK HORSE AT THE BLACK HORSE __________________ Golf-My favourite game. While my wife plays I'm in the workshop.

15-10-2021, 03:04 PM	#670
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	Today I thought I'd wage war on sloppiness- the side stand and the gear change VIDEO OF THE PROBLEM Play on the side stand pivot has a couple of consequences. Firstly it allows the return spring to pull the stand outwards especially in the up position and this can foul the gear pedal movement Secondly it allows the bike to lean dangerously far over when in the down position I used an 18x22x30 bronze bush from Henderson Bearings I dont have a lathe or milling machine so I used a 21.5mm Blacksmith drill to open up for the bush. Because the drill wandered a little I didnt need to ream the hole further and the bush was a good tight push fit. Not pretty but effective and quite adequate for a simple pivot. The revised pivot bolt is made from some M12x1.25 fine thread with a plain washer welded to the head and a couple of flats so you can turn it. The reduced height head allows the return spring plate to pass over the pivot point and thereby remove the automatic spring back of the sidestand that leads to those unfortunate dropping the bike moments. The consequent risk of moving off with the side stand down is mitgated by a lockout relay that cuts the ignition if the transmission is engaged with the stand down, but there are further lockout relays that allow the bike to be started with the side stand down, but out of gear. I also ordered a couple of rod ends to get rid of the gearchange slop, its still not perfect because theres a little play in the pedal bush too __________________ Golf-My favourite game. While my wife plays I'm in the workshop.

12-10-2021, 08:30 AM	#664
350TSS Too much time on my hands member Join Date: Jan 2013 Location: Shipbourne Bike: M900 Posts: 1,419	You have made a superb job of it - you should feel well deservedly pleased

12-10-2021, 11:36 AM	#666
Luddite Registered User Join Date: Aug 2011 Location: Southampton Bike: M1100evo Posts: 2,465	leonlc had some ZDM and E3 decals made by classicmotorcycledecals2 on eBay so you could PM him for location details. (You might be able to work out the position of the ZDM sticker from the photo in his first post.) http://www.ukmonster.co.uk/monster/s...ad.php?t=58828 If you haven't already printed your seat sticker, they also do one of those too. https://www.ebay.co.uk/itm/DUCATI-M9...-/164359095835

12-10-2021, 04:59 PM	#669
Jam911 Registered User Join Date: Jun 2021 Location: Stratford Upon Avon Bike: Multiple Monsters Posts: 288	Gorgeous - Well done

15-10-2021, 03:57 PM	#671
Darkness . Join Date: May 2007 Location: Stockbridge Bike: M900 Posts: 1,984	Eek! Look at the state on that gear linkage tube!! A previous owner of one of mine used an economy solution to the wear in the wishbone joints: (They didn’t buy the new ones!) __________________ Original and Best since 1993

15-10-2021, 07:05 PM	#673
Darkness . Join Date: May 2007 Location: Stockbridge Bike: M900 Posts: 1,984	That’s more what I expected from you Patrick! Do you like the “adjustment” of the bronze bush with a hammer and nail? __________________ Original and Best since 1993