Author Topic: #7 joins the fleet  (Read 311 times)

Prophet Of Doom

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#7 joins the fleet
« on: March 27, 2019, 01:13:16 AM »
Just bought this one sight unseen over the interweb.
Unsurprising it's an Australasian version XZ550R 16R. 

I wonder what wifey will say when she gets home?

Walt_M.

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Re: #7 joins the fleet
« Reply #1 on: March 28, 2019, 08:09:11 AM »
Details? Year, mileage?
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fret not

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Re: #7 joins the fleet
« Reply #2 on: March 30, 2019, 02:14:57 AM »
Hope she likes red.  :police: :angel:
Retired, on the downhill slide. . . . . . . . still feels like going uphill!

Prophet Of Doom

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Re: #7 joins the fleet
« Reply #3 on: March 31, 2019, 02:03:10 AM »
So Iain and I picked up the bike yesterday.  Well that's what you get when you buy a bike sight unseen.  The only good thing about it is that is has live registration (title), and it rolls. 
78,000 km and I think every one of them must have been in the rain.  There's rust everywhere.

It's a lot worse than it looks in the pictures.  The engine has been swapped out for a XZ400 engine. as has some of the switch gear.  Tank is in a bad way, and overpainted with what looks like red fence paint and a ton of bog.  Every bit of rubber has turned to dust.  Stator is shot, starter is shot, battery is dead, doesn't fire


There's nothing for it, I'll have to do a full ground up restoration.  That's OK, ever since Bobby "Re-vision" Crabb suggested a full museum quality re-build  I've been thinking I'd like to be involved.  I just didn't think it would be me doing it. 
 


So yeah, anyone willing to donate some new parts or factory quality re-furbished items just send me a message.

Walt_M.

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Re: #7 joins the fleet
« Reply #4 on: March 31, 2019, 08:44:03 AM »
That is going to be some project. Are you going to keep the 400 engine or go back to 550?
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Prophet Of Doom

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Re: #7 joins the fleet
« Reply #5 on: April 07, 2019, 04:22:54 PM »
I happen to have a couple of partially dismantled 550 engines in the garage.  I will try and fuse these together to build one.




Prophet Of Doom

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Re-Keying
« Reply #6 on: April 13, 2019, 06:23:13 AM »
First order of business on this bike is to sort out the keys.  The ignition tumbler had been replaced at some point so didn't match the petrol cap or the seat lock.  It was also gummed up with years of crap.

Equipment needed:
10mm socket to remove lock
1 medium JIS Screwdriver
1-2 spare locks (for wafers) and ball-bearings/springs that get lost on the floor
Cleaning solvent
DriGlide Spay
CRC contact Cleaner (for the electric parts)

Access the lock by removing the upper triple tree, and open the headlight to disconnect the wiring.
I pulled the ignition lock and a couple of screws and I had it apart.  Once all the obvious bits have been pulled out, the tumbler comes out by pushing a brass spring-loaded tab in towards the centre, then the lock out towards the rider.  The lock is a wafer type - it uses sliding wafers rather than pins so it's a lot simpler to re-key (and to pick).  Take care though else you will have springs and wafers everywhere.  The brass tab is on the same side as the wafers so keep it pointing upwards.  A finger on the top as you remove the tumbler stops the wafers in place.  There are you tube videos on wafer locks, but none I found with the brass tab. Hondas use circlips instead.

With the key inserted,  all the wafers have to align to the body in order to turn.  Pulling apart some spare ignition units I found wafers of the right size and swapped them in.  Cleaned and sprayed the insides liberally with Dry Glide (Doesn't attract dirt like oil does), and job done.

The only tricky thing in re-assembly was the spring/ball bearing from a small catch.  Fitting is not immediately obvious. The way to fit this is to insert the small metal piece without the spring or ball, Align the indent from the hole in the casing, then insert these both from the outside,  Spring first.  It's locked in place once the metal piece is pushed into position.

All together and looks and operates like new, but with the correct key.  The back plastic part was hard and brittle and I broke 2 spares trying to disassemble.  I ended giving up on the thought of a thorough clean - instead I flushed quantities of CRC Contact cleaner through the holes to clean up the electrics.  Gave the connectors a clean and polish.

Finally, I made a replacement label for the back with the new key number.

Loverly
« Last Edit: April 13, 2019, 07:47:08 AM by Prophet Of Doom »

Walt_M.

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Re: #7 joins the fleet
« Reply #7 on: April 13, 2019, 07:45:03 AM »
I have done that. As you know,  it is very tedious. Step 1 is, sweep the floor! Good job.
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Prophet Of Doom

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Ventilated Piston
« Reply #8 on: June 21, 2019, 10:18:00 PM »
Mostly I've been removing parts one at a time, and  either replacing or refinishing them as I go
Now it's time to rip into the engine(s) - I'm trying to build a single 550 engine from my spares as the bike came with a 400cc installed :-(


This was my "best" spare engine.  Low km and working well when removed from the bike - or so I was told.


Walt_M.

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Re: #7 joins the fleet
« Reply #9 on: June 22, 2019, 08:13:01 AM »
I have always appreciated a truthful seller. Bet that was running really sweet.
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fret not

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Re: #7 joins the fleet
« Reply #10 on: June 23, 2019, 04:18:49 PM »
Dang, I bet that was noisy.
Retired, on the downhill slide. . . . . . . . still feels like going uphill!