R45 Re-Commission

[nicholsonj2252]

Got some of the service items out of the way today so oil , oil filter , plugs , air filter , gearbox , final drive and swinging arm oils and lastly valve clearances . Also fitted a new neutral switch as the old one was leaking oil . Unfortunately turned up an issue from the bikes past when I removed the exhaust to find that the right hand exhaust threads were totally shot . I had to cut the nut off to remove it , left hand side came off no issues and was fine . So do I get a second hand head , try and get the threads repaired or just fit one of the exhaust nut modification kits from Motorworks......

Exhaust header nut modification kit

Finned

www.motorworks.co.uk

Siebenrock sell the thread chaser for the larger 40mm exhaust headers but not for the 35mm header on a R45

Exhaust Thread Cutting Tool

This tool is perfect for fixing threads that are moderately to severely damaged but still there. It can be used whenever the exhaust nuts are removed…

www.siebenrock.com

Does anyone know a source for what I think is a M46 x 2.0 thread (40mm header is a M52 x 2.0) - or even better does anyone have one I could borrow ?

 

[Paradiso]

Within the last year I had the thread from an R65 repaired/replaced by Roger Bennett Engineering in Huddersfield (near the football stadium). He machined off the damaged thread and fitted a bronze thread/sleeve. Price was very reasonable and he did a good job.

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[nicholsonj2252]

Within the last year I had the thread from an R65 repaired/replaced by Roger Bennett Engineering in Huddersfield (near the football stadium). He machined off the damaged thread and fitted a bronze thread/sleeve. Price was very reasonable and he did a good job.

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If you don’t mind me asking what was the cost of the repair ?


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[Paradiso]

I had a couple of jobs done. Can't remember exactly. It was less than £100. If the valves & guides are good in the head you have, it's worth doing.

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[nicholsonj2252]

Decided to go with a refurbished head complete with valves from Motorworks , good threads and new valve guides and a 6 month guarantee , so hopefully its OK

 

[nicholsonj2252]

An image search suggests that it's an odd looking sealing washer that looks like this?

The rubber diaphragm does have that fancy shape but I think just a flat plastic washer 48mm diameter by 1mm thick would do the job - just need to find something suitable

 

[nicholsonj2252]

Lots of cleaning and checking of parts today , thankfully no more gremlins discovered so far....

 

[nicholsonj2252]

Got all of the front end sorted and re-assembled : master cylinder re-build kit , brake calipers stripped and rebuilt , head bearings cleaned & re-regreased , replacement horn fitted , forks stripped and re-assembled with new oil and new handgrips

Next job is to strip the rear end down and check swinging arms bearings , lube splines & check rear brakes

Replacement RH cylinder head should be with me by end of next week hopefully

 

[dicktheleg]

Looking good John

 

[nicholsonj2252]

Looking good John

Thanks for helping me out with the replacement horn , much appreciated

 

[Montydog]

Looks very good and an interesting read


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[Jockser]

That’s a lovely looking wee bike

 

[DrFarkoff]

N.B. THose ATE alloy callipers are notorious for Sticking

Good News is Standard Brembo of the era bolt straight on in place of them

@nicholsonj2252 Did you get a Tool Tray sorted ?? I may have one here and maybe a scruffy tool roll and tools

 

[nicholsonj2252]

N.B. THose ATE alloy callipers are notorious for Sticking

Good News is Standard Brembo of the era bolt straight on in place of them

@nicholsonj2252 Did you get a Tool Tray sorted ?? I may have one here and maybe a scruffy tool roll and tools

All sorted with tool tray , pistons are all free and bores good so fingers crossed they don’t seize , thanks for the tip on brembo calipers


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[nicholsonj2252]

Rear end stripped and everything OK

 

[Majesty]

Looking good John.

 

[Kenny]

We need an update !

 

[nicholsonj2252]

We need an update !

I’m afraid working away from home , looking after grandchildren and waiting on parts have brought the build to a standstill. Motorworks only send the heads out for refurbishment once they have sold them and it’s a 2-3 week turnaround. Hopefully I’ll get the replacement RH head this week and I can make some good progress at the weekend.


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[The Other PaulG]

Excellent - watching with the usual awe.

 

[nicholsonj2252]

Rear end of the bike re-assembled after a good clean and inspection

Swinging arm bearings checked and re-packed with grease . Brake shoes all OK as is drum bore . Final drive all OK

Rubber foot peg rubbers all cracked and brittle so new ones on order

Plan to get the centre and side stand removed next to check and lube the pivots and fit new springs

Still waiting on the replacement head from Motorworks but will get the old one removed