Custom Fighters - Custom Streetfighter Motorcycle Forum banner

281 - 300 of 331 Posts

·
EXUP
Joined
·
241 Posts
Discussion Starter #281
Small update from the last few days.

Made some brackets to hold my radiator guard in place utilising the original mounting holes.







Then my HT leads arrived, but they had sent me red ones, not blue as ordered!!



So instead of installing them I decided to spray up all the bits and bobs that I could.





Did a little bit of wiring extension to the radiator fan and also took the oportunity to extend the rear brake light wiring as the existing connector is in the firing line for crap from the rear wheel!

(apologies for the below pic, but Photobucket have changed their edit function and I can't see a draw function to add an indication line to the connector I mean, so focus blurred instead)







And whilst the foot mount was off I removed the hose stop on the rear master cylinder as you can guarantee it will be in the way of the hose when I get around to mounting it!





Anyhow the postman arrived with the flexihose so with the rad back in place temporarily I cut the bottom hose to length. ( it looks very blue in the pics, but is less so in real life)





Fits nicely and without kinks, but its too stiff to do the top hose, so I have just ordered a couple of elbows to sort that out along with a hose adaptor and joiner.

more when they arrive :D
 

·
Back at it for now.
Joined
·
1,545 Posts
Hey is that the original radiator? That is kind of what I am looking for to swap out with the my GSXR 750. The hose nubs are in the right places and it has a filler cap with temp sender and fan switch bungs. Let me kow what it is so I can start looking for one. Thnks
 

·
EXUP
Joined
·
241 Posts
Discussion Starter #283
Hey is that the original radiator? That is kind of what I am looking for to swap out with the my GSXR 750. The hose nubs are in the right places and it has a filler cap with temp sender and fan switch bungs. Let me kow what it is so I can start looking for one. Thnks
The radiator is from an 89/90 FZR1000 R exup.
Be careful if your looking on Ebay as the 87/88 FZR1000 Genesis is sometimes listed as an Exup and the later 91/95 RU exup is taller.

Also note that the main outlets have been rotated on mine and an extra inlet added to the bottom right.

see below pics for comparison

Mine



87/88 FZR 1000 Genesis



89/90 FZR 1000 R Exup (same as mine but without lower right inlet)



91/95 FZR 1000 RU Exup (taller than mine but with lower right inlet as standard)

 

·
Back at it for now.
Joined
·
1,545 Posts
Yeah, wouldn't have known all that. Thanks for pointing it out on your thread. Very informative. I just need the two ports and the bungs for the two switches. I will keep my eye out for the right one to come up. Thanks again.
 

·
EXUP
Joined
·
241 Posts
Discussion Starter #285
No worries Stainr, happy to help ;)

Anyway, the replacement blue HT leads arrived



So I set about replacing the stiffer copper cored ones, its not obvious but the red ones on the left are "resting" in their installed orientation, where as, in comparison, the blue silicone ones are infinately more flexible.



This in itself made installation a breeze, just needed to smear the outside of the lead with WD40 otherwise it "grabbed" the inside of the spark cap as it was screwed onto the internal post.



It doesn't look it but the revised splash guard and trimmed wiring has helped immensely with the re-installation of the connections.



then my elbows and hose adapters arrived so I could replace the top hose.



I reckon the hose adapter will go a long way in helping the flow when comparing the bore to the original DIY effort.



Got it all mocked up





then ordered the relevant clamps required, but unfortunately I was sent a mix of two types, I ordered the style on the left, but only got sent one of these and all the rest were the type on the right, so I am currently waiting for the replacements to arrive. Not been having much luck in the online ordering department lately.



Any way, in the meantime I decided not to "ruin the ship for a ha'peth of tar" and investigated replacing the adapted water cooled oil filter hoses.
one of them is a straight run, but the other takes a rather tight route round the block and between the casing and front lower engine mount!







So I ordered a 1m length of 13mm flexihose that would hopefully be long enough to do both lines along with some stainless jubilee clips.



Luckily it was flexible enough, more so than the 25mm hose, to make the curves required and long enough to replace both hoses from the one length.

to give the hose a bit of extra abrasion protection where it passes the front engine mount I reused the plastic spiral wrap and held it in place with tape.









All looks good so I took my rad guard outside and gave it a coat of paint



And installed it on the rad along with the new fan switch and temp gauge sensor ready for refitting.





Refitted the expansion bottle and rad, just need to wait for the clamps to arrive so I can fill her up and test for leaks. :D

 

·
Just Dutch
Joined
·
46 Posts
man I like this moped and love you for building such a superb bike, with nice and cool stuff.
I only dont like the radiator cover but thats personally, no furthe offense :D
Cool blue hoses, looks very well.
 

·
EXUP
Joined
·
241 Posts
Discussion Starter #287
man I like this moped and love you for building such a superb bike, with nice and cool stuff.
I only dont like the radiator cover but thats personally, no furthe offense :D
Cool blue hoses, looks very well.
No offence taken bud, thats the whole point of this site, its about individual tastes, otherwise we'd all be riding exactly the same thing.

Anyhow,

As the suns shining I thought I'd tack everything back on for an updated pic, or at least one's that weren't taken in the confines of the garage :D













Well that should give me the incentive needed to "git er dun" the list of things to do/buy is getting smaller!!
 

·
EXUP
Joined
·
241 Posts
Discussion Starter #292
Sorry if this has been addressed already, but are you going to gloss the tank to match the tail? Seems to be just a bit more matte.
No worries Rock, in answer to your question, the tank is matt black from the previous owner.



the seat unit was light blue, you can see the original colur on the inside below



but both upper and lower were repainted badly in a dark blue (almost black) before I purchased them.



The rear seat cover is actually gloss black, seat cover is top left.



And the front mudguard is a very dark green



They are all not far off black so they dont look out of place together unless they are in bright sunlight (apart from the matt black tank of course :D )



I am going to get her painted, but the decision on that has still to be made. Iwas going to go orange like Spondons FZ



Link to Spondons build here

Although I do like the idea of wrapping it in carbon fibre a la Knifemaker87

Link to Knifemaker87's Carbon Fibre Porn





Or go gloss black, or a blue not far off the hose colour (not sure if that would be too much though??!)

we'll see :D
 

·
EXUP
Joined
·
241 Posts
Discussion Starter #297
You can do whatever color carbon you want...

Oi, Spdu4ia, you've cost me enough already!!

mutters under breath "blue keyfob..dammit!" :LolLolLolLol:

The jury is still out on paint, I do like the carbon idea, but normal carbon not coloured, plus I have to sort out side panels, but I have an idea for these.

Anyway, whilst I was waiting for my clamps to arrive I thought I would tackle a few jobs on the rear end.

Remember this?



Well I decided it was time to fit it, however in its raw form it was too wide and couldn't be riveted to the backplate on the swingarm.





But with a curve introduced it would allow me to fit it.
So out with the heat gun and spare tyre to use as a former to get the bend right.





However this didn't work as I could only heat a bit at a time.
So into the kitchen I go and sling it in the oven at 150C for 10 minutes :LolLolLolLol:
held over the tyre former with welding gloves and I ended up with this.



Needed a bit of cleaning with wet and dry to remove the finger marks and material from gloves , but its the shape I needed.

so out with the rivet gun.





Whilst the rear wheel was out I fitted the replacement chain adjuster bolt I bought 2 years ago, after removing the lettering from the heads with a flap wheel.







Next I rummaged through my assortment of hoses to see if I could find a rear brake line that fitted, unfortunately the remaining Triumph line ( other two are used on the front) is too long, but a Melvin rear brake line from a GPz500 set I bought on the off chance, fitted the bill.



The handy thing about the Melvin lines is that you can rotate the banjo fitting by 90 degrees without affecting the seal.



So, along with the rear caliper I got from :ebay: I now have a functioning rear brake.





Just need a clip to hold the line away from the can.



Yesterday (Saturday), my replacement clamps arrived



So the next step will be making sure she's water tight and running her up, and maybe, just for giggles, put the old chain on her to see how she rides (just up and down the road) before getting new chain and sprockets, rear tyre, MOT, Insurance, blah blah blah :lol:

Oh, and correcting my wiring error, you remember I replaced/lengthened the rear brake wiring?
well I simply removed the extension and lengthened the existing wiring, whats wrong with that you may ask?
see pic.............what a pillock!! :LolLolLolLol:

 

·
EXUP
Joined
·
241 Posts
Discussion Starter #299
As always - great DIY work Fang. Question on your rear fender: did you just drill a couple small holes in your swingarm to put those rivets in? I don't see any holes on the backplate prior to install.
Yep, drilled two 5mm holes in the back plate.
Not that you can see at the moment, apparently I have exceeded this months viewing limit of 10GB :mad:, still resets to zero in 3 days so all will be back to normal :)
 

·
EXUP
Joined
·
241 Posts
Discussion Starter #300
Morning all, its been a while since my last confession...hang on? that's not right!

I mean, its been a while since my last update :D

So I remedied my wiring cock up





My inserts and spacers for the rad and bars arrived from my machinist :thumbsup:



bar end inserts before



and after machining





mmmmm shiny



so set about installing the bar end weight inserts.



took a while but by using a sanding bit in a cheapo Dremel I managed to enlarge the internal ID of the bars to allow a snug fit of the insert.



drilled a couple of holes to allow for welding



Inserts installed, spot welded, weld smoothed off, job done.











bar ends fitted :D

 
281 - 300 of 331 Posts
Top