5TH Gen Refresh and While I'm in there Disease Rehash

[maxredline]

My god that is a lot of work. If I remember correctly its a silver bike.
Since I have been in limbo I have sold my Red 5th to a nice fella who flew half way across the country to ride it home. I still have my black one I am riding and may give to my son and the Blue one in the trailer that needs a paint job.
You are doing an exellent job on your bike!

[JZH]

Not to get in the way of a good engineering and manufacturing exercise, but the KISS option would be to run both lines directly to the front master cylinder, utilising a double banjo bolt and precisely three M10 x 2mm aluminium crush washers. The cost being the price of two new brake lines.

No intermediary caverns means no intermediary air pockets...

Ciao,

JZH

[mello dude]

Looks familiar!

[mello dude]

Not to get in the way of a good engineering and manufacturing exercise, but the KISS option would be to run both lines directly to the front master cylinder, utilising a double banjo bolt and precisely three M10 x 2mm aluminium crush washers. The cost being the price of two new brake lines.

No intermediary caverns means no intermediary air pockets...

Ciao,

JZH

Totally agree! if I was starting over, would do the 2 line direct and skip the manifold completely... I even was reconsidering that (may still) but spending more $ ?? I already put too much into the stupid red thing.....

In retrospect KISS does win!
What was I thinking? or was I thinking or this or that!

[mello dude]

Replacing OEM brake hose...new SS lines from CoreMoto...good vendor!

Adding a heat shield material since it runs by the header...

Running the line and mount up

[mello dude]

Perma Delete of the Pair Valve airbox nozzle...
Hacksaw off..

Permatex and 7/16 inch bolt, red loctite on nut...

Airbox mounted down, Venturis installed. (yay)

Old air fliter...um.. waaaay overdue to replace (my bad )... Its a BMC, I do like it...

New BMC

In Airbox..

Airbox button up..

[Knute]

Hey Mello Dude,

I'm really digging the work you're doing here! You've inspired me to start purchasing parts for my '04 to clean the throttle body and cooling system refresh. Going with the AS3 hoses as well, however I can't find the tubing you're using on the throttle body, got any info on where you sourced it?

Thanks, Knute

[Knute]

Hey Mello Dude,

I'm really digging the work you're doing here! You've inspired me to start purchasing parts for my '04 to clean the throttle body and cooling system refresh. Going with the AS3 hoses as well, however I can't find the tubing you're using on the throttle body, got any info on where you sourced it?

Thanks, Knute

Never mind on the TB tubing, just found what I was looking for...

Knute

[mello dude]

Took another look at a "mbe" a 2 line direct from the MC on front brakes. Right side is easy, but going to the left side, nothing for me looks "clean" So I am at "Effe" it. This damn bike has to hit the road! Summer's here, panic setting it... aaahhh


Back to the task I hate the most of when working on a bike and that is filling/bleeding a completely dry brake line system.
Keeping the over the top manifold I wasnt getting anywhere, and its being a PIA! So, the next thing... break it down and do a bench bleed.
I threw together a bench setup and one caliper at a time, bleed every last bit of air out of the now empty piston bores. Got 'em done.

Calipers back on the bike, more bleeding...


Left side, right side, back and forth... ..getting close!

Weather is nice, time to ride! Later...

[mello dude]

Bleeding is done! Brake level feels good! The thing is the brakes are dragging a bit...grr... a member suggested to take is out and do some hard braking. See what that does.. It would really suck if I need to tear it down. I have way to much work into these brakes, it was supposed to be a side job... (yeah, right)

Anyhoo, here's the SS lines with the manifold and the dual horns mounted. One is a 4 inch Hella #3BA 002 768-082 and the other is parts bin. It will be buried in the body worke..... I mounted a relay on the fairing stay long ago for the horns.



Curiosity kills the cat and I just had to throw in a battery to test the things... A quick beep beep and HOLY Freaking Bananas! Its loud!
My ears rang after that...

Another finally ....first piece of body/gage trim going on...its been tooooo long!


Rain tomorrow, more work...