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 Post subject: Project.......Joker
 Post Posted: Tue Sep 29, 2015 1:46 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Bought this little beauty on a whim a few weeks ago.
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These are the only two pictures I saw before I bought it, so a deal was struck :eek
I couldn't decide whether to break it or rebuild it as it obviously looks worse in the flesh so to speak.
The best bit on the bike although not to my taste is the paint job on the tank.........
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It looks like it may have been a track bike at some point ..................
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Also looks like someone had a fetish for hand painting gold paint everywhere. just about every bolt head had been painted so I soon attacked that with a wire brush on a drill :mic

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 Post subject: Re: Project.......Joker
 Post Posted: Tue Sep 29, 2015 9:45 am 
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Knob Magnet
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Joined: Sun Mar 05, 2006 9:38 pm
Posts: 9772
Location: Catterick, North Yorkshire
oooooH just what we need, a new project 8o 8o 8o 8o 8o 8o 8o 8o

now GET ON WITH IT :finger

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 Post subject: Re: Project.......Joker
 Post Posted: Tue Sep 29, 2015 11:23 am 
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Hornet Warrior

Joined: Thu Nov 06, 2014 12:44 pm
Posts: 137
Location: Northumberland
Be interesting to see what this turns into!


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 Post subject: Re: Project.......Joker
 Post Posted: Tue Sep 29, 2015 11:50 am 
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Knob Magnet
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Location: Catterick, North Yorkshire
BIG TARTS HANDBAG, if his 900 turbo is anything to go by :rollin :rollin

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 Post subject: Re: Project.......Joker
 Post Posted: Tue Sep 29, 2015 3:01 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
chrisdubya wrote:
Be interesting to see what this turns into!

370steve wrote:
BIG TARTS HANDBAG, if his 900 turbo is anything to go by :rollin :rollin


Got any tips Steve?

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 Post subject: Re: Project.......Joker
 Post Posted: Tue Sep 29, 2015 3:07 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
woodyeee wrote:
Got any tips Steve?


YEP, paint it matt black :rollin

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 Post subject: Re: Project.......Joker
 Post Posted: Tue Sep 29, 2015 3:21 pm 
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Hornet Warrior

Joined: Thu Nov 06, 2014 12:44 pm
Posts: 137
Location: Northumberland
370steve wrote:
BIG TARTS HANDBAG, if his 900 turbo is anything to go by :rollin :rollin


There a build thread for this?!


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 Post subject: Re: Project.......Joker
 Post Posted: Tue Sep 29, 2015 5:09 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
There used to be Chris but I think some of it was lost when the site was updated or something.

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 Post subject: Re: Project.......Joker
 Post Posted: Thu Oct 01, 2015 11:29 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Back to the build. I will be trying to rebuild this one on a smallish budget as I need to buy a few parts just to make it complete.
First parts i have purchased are a standard set of clocks and a speedo drive and cable. I found these on eBay...... £55 delivered for the clocks from Ireland and £5 delivered for a vfr750 speedo drive and cable. I have already sold the Elliot tacho and racetech temp gauge that came fitted on it for £30 so I think that's a bit of a result!

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 Post subject: Re: Project.......Joker
 Post Posted: Thu Oct 01, 2015 11:38 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
A short interlude while parts arrive.....................
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 Post subject: Re: Project.......Joker
 Post Posted: Fri Oct 02, 2015 12:03 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Ohlins shock that was fitted is leaking so needs a rebuild. I have already found a Hagon replacement unit for £120 delivered. Image
Ohlins shock removed........wtf! Previous owner must have been Picasso :lol
I will clean the Ohlins up a little and sell it on so by my reckoning it will pay for the Hagon unit.

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 Post subject: Re: Project.......Joker
 Post Posted: Tue Oct 06, 2015 12:43 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
I have ordered a few top quality parts at the weekend which are coming from .......China :p I have also ordered a pair of O.E. fork seals from Dobles.
Decided to start pulling the front end off and strip down the forks.
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The forks came apart nice and easy for a change!

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Last edited by woodyeee on Tue Oct 06, 2015 1:11 am, edited 1 time in total.

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 Post subject: Re: Project.......Joker
 Post Posted: Tue Oct 06, 2015 1:07 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Gave the fork legs and yokes a clean up ready for a lick of paint.
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 Post subject: Re: Project.......Joker
 Post Posted: Tue Oct 06, 2015 1:10 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
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So glad that hideous gold paint is now gone!!

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 Post subject: Re: Project.......Joker
 Post Posted: Wed Oct 07, 2015 9:33 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
The wife answered the door on our wedding anniversary expecting a surprise ...............well she got one :lol
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New Genuine mudguard £38 delivered from Holland. I have been looking for a reasonably priced/condition used one but some people want extortionate money for basically shite!! I found this new for less than what someone wanted for a damaged one :eek
First impressions are it's a good colour match to the silver on the tank, but I'm undecided on the final colour /paint scheme.

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 Post subject: Re: Project.......Joker
 Post Posted: Thu Oct 08, 2015 8:30 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
A set of go faster Hrc fork seals arrived from Dobles, £11.50 delivered.
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 Post subject: Re: Project.......Joker
 Post Posted: Sun Oct 11, 2015 3:17 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Took the rear wheel out and removed the wheel bearings from both wheels. Dropped off the wheels, and yokes for powder coating. Wheels are going to be gloss black and have chosen sparkling silver for the yokes.

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 Post subject: Re: Project.......Joker
 Post Posted: Sun Oct 11, 2015 3:35 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Had to make a spacer for the new Hagon shock as for some reason the Ohlins shock spacer is to big for it. I just so happened to have a spare gudgeon pin that was off my 900 that is exactly the same diameter. A little bit of magic with the grinder and...............
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I could of ground the original down but that will stay with the Ohlins.

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 Post subject: Re: Project.......Joker
 Post Posted: Mon Oct 12, 2015 1:53 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Removed the exhaust, I was very surprised that none of the nuts/studs were seized..............
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Gave it a little bit of a clean up..............
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Good enough for this project me thinks.

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Last edited by woodyeee on Mon Oct 12, 2015 2:32 am, edited 1 time in total.

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 Post subject: Re: Project.......Joker
 Post Posted: Mon Oct 12, 2015 2:26 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
The bike is fitted with a standard brake light switch but it looks like it's still got the remnants of an old banjo switch................
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I've probably got a spare banjo bolt in my box of bolts somewhere but thought I would just see if I could tart it up a little without removing it. I took a drill bit and drilled into it about 3mm or so. Mixed some bodgers glue (Araldite) and filled it with the epoxy resin.............
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The colour should change a little once it's cured, only took a couple of minutes to do so I'm happy with that .......job done.
I will be removing it later as I will be cleaning the arse end up a little later.

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 Post subject: Re: Project.......Joker
 Post Posted: Mon Oct 12, 2015 9:27 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Just waiting for a few parts to arrive before I do anymore of the build. Parts on order..........
Radiator & fan switch.
Fork bushes.
Wheel bearings.
Speedo drive plastic joint.
Oil & filter.
Lower yoke dust seal.
Electrical connectors.
While I'm waiting for parts there will be another interlude.....
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 Post subject: Re: Project.......Joker
 Post Posted: Tue Oct 13, 2015 9:28 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
£61 of parts arrived from David Silver spares. The genuine fork bushes were cheaper than pattern aftermarket parts! It does pay to shop around.
Top of the range from eBay :p rear wheel bearings £3.90 a pair delivered!
2 x 6 way connectors £4.80
All were next day delivery so top marks to the seller's.
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 Post subject: Re: Project.......Joker
 Post Posted: Fri Oct 16, 2015 11:58 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Not much spare time at the moment but managed to make a start rewiring the main loom clock connectors.

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The main wiring loom had the original connectors changed so I chopped these off and crimped some original type ones back on.
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Once the original type connectors were put back on I turned my attention to modifying a vfr750 clock loom to fit the 600 clocks.
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A little bit of head scratching, soldering and crimping and it's halfway there.
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For some reason Honda decided to used two different size push in bulbs on the clocks so I had to carefully drill out the plastic clock socket to ensure a snug fit.

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 Post subject: Re: Project.......Joker
 Post Posted: Sat Oct 17, 2015 8:58 am 
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WOOF!
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Location: Gainsborough
Need to get over and see this work in progress. :lol

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 Post subject: Re: Project.......Joker
 Post Posted: Sat Oct 17, 2015 11:17 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Scott wrote:
Need to get over and see this work in progress. :lol


It's always brew o'clock here :pissed

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 Post subject: Re: Project.......Joker
 Post Posted: Sat Oct 17, 2015 11:39 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Popped out this morning before work to pick up the parts that I've had powder coated.
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Sparkling silver handlebar clamp.
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Sparkling top yoke.
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Yoke top and bottom.
Credit where it's due, the power coating I've had done is probably the best they have done for me and looks excellent close up........but fugging hell what a barsteward the masking tape was to remove!!

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 Post subject: Re: Project.......Joker
 Post Posted: Sat Oct 17, 2015 11:47 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Managed to get the forks rebuilt with new bushes and seals.
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The fork on the right has a 43mm bit of plastic waste pipe and the old fork seal that I used as a fork seal driver. It does the job a treat :D

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 Post subject: Re: Project.......Joker
 Post Posted: Sun Oct 18, 2015 12:02 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Wheels done in gloss black........
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Front wheel.
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Front wheel rebuilt with bearings, discs and stainless bolts.
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Rear wheel built with new bearings.
And that boys and girls concludes tonight's exciting episode, do sleep well and tune in tomorrow.................
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 Post subject: Re: Project.......Joker
 Post Posted: Sun Oct 25, 2015 4:05 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
A little bit of an update. I noticed on close inspection that the rear disc I purchased had quite a few cracks!!
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A bit of a bugger as I have already left good feedback :Bang
I have already purchased a brand new cheap replacement for £18.99 delivered.
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 Post subject: Re: Project.......Joker
 Post Posted: Sun Oct 25, 2015 4:15 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
A cheap new replacement disc must be safer than a cracked old disc i say.
Managed to get it fitted to the wheel with new stainless bolts.
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All clean and shiny. I don't usually fit old tyres to freshly coated wheels but these have loads of tread left so they went back on.
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I don't think the chain and sprockets have had much use as the renthal rear sprocket looks quite new.

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 Post subject: Re: Project.......Joker
 Post Posted: Tue Oct 27, 2015 2:14 am 
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Hornet Lord
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Posts: 811
Making good progress. Powder coat looks good


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 Post subject: Re: Project.......Joker
 Post Posted: Tue Oct 27, 2015 10:06 am 
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Hornet Warrior

Joined: Thu Nov 06, 2014 12:44 pm
Posts: 137
Location: Northumberland
As above! Looks tasty :)


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 Post subject: Re: Project.......Joker
 Post Posted: Fri Oct 30, 2015 7:41 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
A little bit of progress to report, slowly but surely it's coming along.
The rebuilt forks, yokes, wheel and front mudguard have been fitted. The front mudguard bolted on for a trial fit as it still needs to go for paint job.
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I was thinking about getting two blue lines to follow the theme of the tank.

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 Post subject: Re: Project.......Joker
 Post Posted: Fri Oct 30, 2015 7:49 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
I was only going to clean the swingarm and footrests up but have decided to get them powder coated too........Bang goes the budget! !!
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First remove footrests, sideplates and Swinger.

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 Post subject: Re: Project.......Joker
 Post Posted: Fri Oct 30, 2015 10:17 pm 
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John Travolta (Are you Dancin'?)

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Posts: 1881
With the bearings removed from the Swinger and the footrests stripped of all the associated s hite I popped them to the powder coaters this morning.

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Frame looks a bit grotty back here so i made a bit of a start cleaning and prepping for paint.
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Attacked the sprocket side with some Jizer and a paint brush so looks a little cleaner. Not sure if the gear shift lever seal has been weaping oil so for the sake of £1.99 delivered I have decided to change it.

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 Post subject: Re: Project.......Joker
 Post Posted: Fri Oct 30, 2015 10:49 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
Right then boys and girls this is easy peasy to do...........
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With the 10 mm m6 bolt and retainer removed get a pick or a small screwdriver and prise the seal out.
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Wipe away any oil or crap, smear a little new oil on seal and gear lever shaft.
Slide the new seal then the old seal over the shaft and gently tap the old seal so it pushes the new seal home.
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Refit the retainer and 10 mm m6 bolt.
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Sit back and open a cold one!
And that boys and girls concludes this evenings lesson :mic

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Last edited by woodyeee on Mon Nov 02, 2015 8:00 am, edited 1 time in total.

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 Post subject: Re: Project.......Joker
 Post Posted: Sun Nov 01, 2015 11:55 pm 
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Hornet Lord
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Nice work. If only all seals were this easy :clap


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 Post subject: Re: Project.......Joker
 Post Posted: Mon Nov 02, 2015 8:24 am 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
Posts: 1881
To be honest they don't get any easier than that...........and to think people would pay good money at the garage to change one of those.


Ordered a new radiator from china a month ago and no sign of it arriving, the tracking number does not work :Bang so I've emailed the seller to see what the crack is :help
Picked up the powder coated swinger and footrests etc. but not had time to unwrap and look at them due to work. Only took them a day and a half turnaround :D

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 Post subject: Re: Project.......Joker
 Post Posted: Mon Nov 02, 2015 4:17 pm 
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Hornet Warrior

Joined: Sun Jun 03, 2012 12:26 pm
Posts: 140
Hey. Enjoying the thread. Very satisfying seeing many grubby things put right.

One question though - What is going on with the tank? If it was me I would sell it and get a clean stock one but that's just my taste.


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 Post subject: Re: Project.......Joker
 Post Posted: Mon Nov 02, 2015 7:16 pm 
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Hornet Lord
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Joined: Fri Jul 17, 2015 7:02 pm
Posts: 636
Location: Somerset
It's nice to watch your progress but you're making me feel bad for not getting on with mine.

One tip I was given for installing new gear shift shaft seals was to put a small patch of cling film over the splines before pushing on the new seal. The cling film is supposed to protect the seal from the sharp edges of the splines. :)


Last edited by knee_jerk on Tue Nov 03, 2015 9:50 am, edited 1 time in total.

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