Expresso front wheel rebuild

[Duane Ausherman]

So how did it ride? Just consider this a test of very light oil in your forks. What can it hurt?

Thanks for making me feel better George. Fork-oil in the brakes, on the other hand ......

I drained the legs. Now struggling to replace the stripped damper nipple. I have spare damper rods,... but can't get the nipples to undo, even with heat. This was meant to proceed quickly ....

It is common for the nut to strip on the threads on the bottom of the damper. This is from overtightening. It is a pain to get it off.

[Chuey]

Getting the calipers apart was a challenge. I took them from my R100S spares bike, its brakes were tragic and since I took it off the road the parts have sat around for 5 years. I searched the forum and found a tip to heat the caliper and then use compressed air. Piston sure pops out with a bang .... there are probably safer ways?


008

ps Any opinions on pitting of the piston? One is too far gone, but the other (pic) only has some pits above the seal line.

On ebay, motogodojo, a seller, has a NOS brake piston if you look at his "store". It seems reasonably priced.

Chuey

[Mal S7]

Thnaks Chuey. Saw some things but not any brake piston?? Maybe someone beat me to it.

Happy to have got my chewed nipple off though. Had a time of it working out how to hold the damper rod so I could unscrew that thing. Came up with this:-

Tight fitting pin-punch. It only just fits in the hole, there is a little spring in the rod that stops it getting right through.



and then sacrifice a 9/16 A/F spanner to BMW Baal



Dremel ground the inside til it just slides over the rod and then carved a slot. Fits beww-diful



and works like this, squeeze them spanners together and hey-presto



Ed Korn eat your heart out

[Deleted User 62]

Well Done!

[ME 109]

How about, 'the only thing that brings my baffling stupidity undone is my brilliance'

[Mal S7]

Well I got it reassembled, with fork oil this time! Felt like too much bearing pre-load on the front wheel when I tightened the axle, so I enlarged the hole in a spare rocker shim, dropped that on and mixed and matched spacers and got it all happy.

Then I went for a ride out on a quiet country road. It span up OK and then suddenly turned into a dog with one lung; I barely made it home. Got some junk out the carb float bowls, took the tank off and checked the wiring ( been stopped by coil wires coming loose before). Don'tcha ever wonder why we don't just buy something shiny and new and be done with it? What is it with this irrationality?

But this morning it seems to be running well and I hope to get away tomorrow for a run up North via Kaputar NP and Copeton Reservoir. See some places I've not seen before and catch up with my bro'.
Fingers crossed!

[Airbear]

Neat workaround, Mal.
As to why we do it, the best I can come up with is to do with what we see when we look down whilst riding. Yep, jugs. Yer won't get that with a Yamazooti.
Have a great ride.

[Mal S7]

Neat workaround, Mal.
As to why we do it, the best I can come up with is to do with what we see when we look down whilst riding. Yep, jugs. Yer won't get that with a Yamazooti.
Have a great ride.

Thanks Charlie. I did have a beaut ride and yes, meditated on jugs at times I must confess. Can highly recommend the ride through Mt Kaputar National Park. Great scenery, quiet roads. Giant fat cattle roaming the roads is the local speed control method, more effective than coppers or cameras for keeping you mellow. Schtarker ran well but for the odd carby full of crap still coming through. I need to clean the tank and check the petcock filters, from trial and error symptoms I think one is clogged and the other might be broken off ...

The clutch cable kindly waited til I was at my destination before snapping.

Apart from that it ran strong and for the first time in ten years a completely oil tight motor! I'd always blamed the infamous push rod tube seals but tried torquing the sump bolts before I left (something I read here, or on advrider). My garage would have a lot less stains had I done that years ago. Living and learning.

cheers Mal

[Deleted User 62]

Don't forget to grease the pins or barrels that hold your cable ends, or premature failure may result. DAMHIK

[Major Softie]

Don't forget to grease the pins or barrels that hold your cable ends, or premature failure may result. DAMHIK

DAUHWAK




(don't ask us how we all know)