Slow Monster rebuild

350TSS · 26-02-2020, 05:40 PM

Half term and trips to see the other sprogs at university has meant no progress over the last 7 days.
First I finished off the battery tray, cutting the opening in the top and removing the half a sharps bin I used to mold the base. Then I positioned the starter solenoid and the RCD.

Next I tackled the mounting arrangement for the regulator/rectifier. I started by thinking I would use a 6mm aluminium plate but after seeing that it would have to have 3 bends in it I decided to make it out of CF. A cardboard template was made first followed by a sheet of 1mm polypropylene which was cut to the shape of the cardboard template then hot glue gunned to some 3mm polypropylene to give the mould some rigidity when stippling the resin. 5 laminations in total were used.
This is it

Next I moved onto fitting the clutch and encountered 2 problems, the first is I need to make a holding tool so that I can torque up the centre nut and the second which was a bit concerning is that the clutch push rod will not go through the gearbox shaft. inserting it from the slave cylinder end it goes in about 25 to 30 mm then hits a restriction which I assume is the small needle roller bearing inside the shaft. I cannot see inside the shaft to see what the obstruction is but I assume the cage is damaged and not letting the push rod through.
I have read these are a bugger to change and in any event the alternator case will have to come off again.
Lots of other little but time consuming jobs done but loads more to do together with the above has caused me to revise my ETTC upwards again to 135 hours

26-02-2020, 05:40 PM	#11
350TSS Too much time on my hands member Join Date: Jan 2013 Location: Shipbourne Bike: M900 Posts: 1,419	Half term and trips to see the other sprogs at university has meant no progress over the last 7 days. First I finished off the battery tray, cutting the opening in the top and removing the half a sharps bin I used to mold the base. Then I positioned the starter solenoid and the RCD. Next I tackled the mounting arrangement for the regulator/rectifier. I started by thinking I would use a 6mm aluminium plate but after seeing that it would have to have 3 bends in it I decided to make it out of CF. A cardboard template was made first followed by a sheet of 1mm polypropylene which was cut to the shape of the cardboard template then hot glue gunned to some 3mm polypropylene to give the mould some rigidity when stippling the resin. 5 laminations in total were used. This is it Next I moved onto fitting the clutch and encountered 2 problems, the first is I need to make a holding tool so that I can torque up the centre nut and the second which was a bit concerning is that the clutch push rod will not go through the gearbox shaft. inserting it from the slave cylinder end it goes in about 25 to 30 mm then hits a restriction which I assume is the small needle roller bearing inside the shaft. I cannot see inside the shaft to see what the obstruction is but I assume the cage is damaged and not letting the push rod through. I have read these are a bugger to change and in any event the alternator case will have to come off again. Lots of other little but time consuming jobs done but loads more to do together with the above has caused me to revise my ETTC upwards again to 135 hours