Winter project

This is the place to show off your photos / details of your own trike build or resoration profect.
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firebob22
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Winter project

Post by firebob22 »

Hi all, well here we go again! Decided to put myself through the misery of another build just to keep me out of mischief during the long winter months.
Found a donor bike on fleabay & got it delivered last week. It's a 1996 Yamaha XJ900s Diversion, in fair condition with a few bits missing. It's a decent runner & as most of the back end will be removed, haven't got too much to worry about at the back. It had a ridiculous looking bikini nose fairing & crappy dual headlights held on with wire & industrial looking clamps. First thing to do after ditching the above is to renew the fork oil seals as they're peeing oil all over the place. Really cheap bike so i'm not complaining. Gathering parts to start the build & got a great Reliant axle off of Old git (Cheers again mate)
so it won't be too long before the great cutting begins. I'll keep you posted & if anyone's after a rear wheel, bevel box etc., give me a shout & you can have 'em for nowt. To that end, has anyone got a windscreen for one of these? Got an original fairing, headlight & frame on line but missing a few parts. Take it easy all. Bob. :thumbsup:
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Some mornings it's just not worth chewing through the restraints! :eek:
Davey the punk
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Re: Winter project

Post by Davey the punk »

Enjoy the build looking for word to see pics of the build
Born a rocker die a rocker :triker:
firebob22
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Re: Winter project

Post by firebob22 »

Hi all, after gathering parts to replace the fork oil seals, on inspection everything inside the forks was buggered. So decided on a complete front end rebuild which included replacing the head bearings as well. Oh what fun was had getting the top race out of the steering neck! Decided to use a Dremel to cut a slot in it & then fashion a dog leg tool/drift to whack it from below which worked, hurrah! All went back together ok after making various odd tools to assist in locating bushes etc.
Painted the bottom legs black & also the wheel which will eventually match the rear ones i've got. New discs & hardware & a new tyre complete the ensemble.
As quite a few parts from the front end were missing, i've sourced the fairing & it's carrier from fleabay & now sorting the wiring back to how it should be. We laughed at the "Stevie Wonder School for Amateur Electricians" when pulling all the insulating tape & twisted wires with no connectors from the loom, but hey-ho, what else would i be doing?
Next up is the bars & instruments/switchgear, can't wait to see what's inside them!
Take it easy all. Bob. :beer:
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Some mornings it's just not worth chewing through the restraints! :eek:
Davey the punk
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Re: Winter project

Post by Davey the punk »

Keep u busy all winter :thumbsup:
Born a rocker die a rocker :triker:
Andy from Sandy
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Re: Winter project

Post by Andy from Sandy »

I was speaking to a Harley tech about neck races and the tool available for removing them. The guy said if it works on first knock okay else he does the same as you and slot them with a Dremel.
Special tool maybe works, Dremel definitely works!
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Doc.
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Winter project

Post by Doc. »

I've been working for a couple of months at a Bike Shop a few miles from me, they deal mostly with Harleys.
They have several types of Bearing Race Pullers.
This type is pretty good for most Ball/Roller Bearings (one-piece types), and not expensive.
Image

For the Outer Races of the 3-part Taper Rollers, you'll need another type of Tool.
Image
They're around £50

Most (Factory) Frames usually have a cut-out (or two) in the Shoulder where the Bearing Race sits, so you can get a Drift onto the Race itself.
Image

Without that, you'll either need to slot the Race (Dremel/Grinder), or Weld a Bolt or lump of Steel Bar/Rod across the Race, and knock on that.
Sometimes, you can just run a bead of Weld round the inside of the Race, and when it cools, it will contract enough to just drop out.

The Inner Race on the Lower Yoke can be tricky, but there are Tools for that too.
Image
firebob22
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Re: Winter project

Post by firebob22 »

Thanks for the replies chaps. The bottom of the steering neck on the frame on the XJ900s has two slots manufactured in the neck to facilitate the removal of the race, not so for the top race, go figure! Everything else came apart with relative ease & after making some suitable sized drifts to put the new taper bearings in, it all went back together with not much swearing. I made a puller to get the new races into the neck from some threaded bar & thick steel plate, worked a treat!
Next on the agenda is the front calipers & lines, then i can start to dismantle the rear end & reconfigure the swingarm to take the modified axle. I'll keep you posted. Bob. :beer:
Some mornings it's just not worth chewing through the restraints! :eek:
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