Noob attempts full B&C system flush [hilarity ensues]

Started by SA14, Saturday, 19 September 2020, 05:19 PM

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SA14

Quote from: KiwiCol on Sunday, 20 September  2020, 02:34 PM
Great it's out, how's the top of the reservoir look?   I doubt Bunning would have what's required, a Fastener specialist will have it.

Extractor spin it out pretty easily. Didn't have to drill down far. Yeah, I agree on Chunnings probably not having anything that small but might get lucky in a kit. I'm thinking small hinge screw or something. Anything that'll get me out on the roads today.

SA14

Shock and awe!

They had M4 bolts in stainless (plus Allen head bolts from M5 and up - good to know). I bought two lengths (one matches perfectly!) and a bunch of washers to make sure I cover the chamfered hole in the cover completely. I'll file down the longer ones if needed but I'll be riding today for sure...unless I farque up the front brake flush but confidence is back up.

KiwiCol

Might be a bit of overkill on the bolts n washers, but it'll work,   -     till you can get the right stuff.
😎  Always looking for the next corner.  😎

SA14

Screwed in the longer bolts and there's plenty of thread to accept them so I'll use the longer ones. The fatter countersunk washers look a bit agricultural but the smaller stainless washers seem to fit nicely even if they do sit at the top of the countersink in the lid and to be honest it doesn't look totally out of place. They cinch on nice and tight and for the lid it's plenty strong enough and full stainless is a bonus.

grog

Well done mate. Some nice little countersunk stainless allen keys will look better. Must get some myself, will look good with my polished caps.

KiwiCol

Just happens I took a pic of my 'dash' today as well.

😎  Always looking for the next corner.  😎

froudy

Always put a dab of Coppaslip or better still, Nickelslip grease on the bolts to prevent future seizing. Countersunk Allen bolts will look far nicer :onya:
Assumption is the mother of all fuck ups!

SA14

Thanks to all who pitched in - it's all done!

Clutch flushed and bled
3 x brakes flushed and bled
Oil changed (after 500km flush with Castrol)
Oil Filter Changed
Exactly perfect amount of Gulf Western Syn-X 3000

Providing it all still works when I next go for a ride I'm a happy chappy and a little bit chuffed. All levers feel firm. I tested 1st gear engagement and pulled the clutch in and out and it works. Road test is the real test of course but I think I did it.

Even my dog winked at me. A man, a dog, a big block bike, a shed and I smell of oils. I even left a foot print in the kitchen carpet. I believe everything is as it should be.

Quote from: froudy on Sunday, 20 September  2020, 05:21 PM
Always put a dab of Coppaslip or better still, Nickelslip grease on the bolts to prevent future seizing. Countersunk Allen bolts will look far nicer :onya:

100% agree. I'll get some this week. This was just an emergency measure - they look ugly as but functional and I just wanted to finish it and go for a ride today but I missed that boat because it's dark and raining now. Will be wet all week they say although they totally stuffed up this weekend's weather forecast. Was supposed to be rain and stormy but it was blue skies and warm both days until just now.

Quote from: KiwiCol on Sunday, 20 September  2020, 05:20 PM
Just happens I took a pic of my 'dash' today as well.

Holy moly! That's a lot of tron! I was wondering about setting up an iPhone holder and charger. Later, for now I enjoy "no phones" while riding. Although some Judas Priest (or Saxon) tunes would be nice e.g. Riding In The Wind.

Quote from: grog on Sunday, 20 September  2020, 05:13 PM
Well done mate. Some nice little countersunk stainless allen keys will look better. Must get some myself, will look good with my polished caps.

Totally going to get some proper countersunk allen heads - preferably in black with the stock black caps. I'm pretty choosy about where I place my bling. Point and counter point as the design guide always says.

Eric GSX1400K3

Well done SA14, I reckon you've got the cleanest set of internal brake lines you can get.  For stuck screws or bolts, I always try to tighten them up a fraction, this unlocks them normally. 

Try model or hobby shops, they normally have all sizes of these small screws and bolts.

Vessel JIS screwdrivers are the bomb, I bought the full set, 135 delivered, including impact ones, they just work.

Bleeding brakes is pretty easy, ive tried the vacuum kit and agree its a piece of crap.  Even on my modern high tech Landrover i use the old school clear tube into a jar with absolutely no issues. 

I follow the same principle as on cars and work from the furthest to closest to the reservoir.   I also put a new master cylinder service kit through it, includes new rubber seals, and you can strip out the master cylinder and clean it out properly.  Clutch master cylinder is exactly the same, and the slave cylinder can also be serviced.

Glad you've got your first gear sorted, you'll be happy with gulf western oil. I think my sump plug is still original, never leaks, just dont overtighten.

I try to take one day at a time, however sometimes several days catch up with me at once.

SA14

Quote from: Eric GSX1400K3 on Sunday, 20 September  2020, 10:06 PM
Well done SA14, I reckon you've got the cleanest set of internal brake lines you can get.  For stuck screws or bolts, I always try to tighten them up a fraction, this unlocks them normally. 

Try model or hobby shops, they normally have all sizes of these small screws and bolts.

Vessel JIS screwdrivers are the bomb, I bought the full set, 135 delivered, including impact ones, they just work.

Bleeding brakes is pretty easy, ive tried the vacuum kit and agree its a piece of crap.  Even on my modern high tech Landrover i use the old school clear tube into a jar with absolutely no issues. 

I follow the same principle as on cars and work from the furthest to closest to the reservoir.   I also put a new master cylinder service kit through it, includes new rubber seals, and you can strip out the master cylinder and clean it out properly.  Clutch master cylinder is exactly the same, and the slave cylinder can also be serviced.

Glad you've got your first gear sorted, you'll be happy with gulf western oil. I think my sump plug is still original, never leaks, just don't over tighten.

Thanks, appreciate the nod n' wink. The screw head must have already been damaged I reckon because it never gripped. It just slipped from the first turn. Will definitely look into a set of Vessels as I reckon the problem started by me using pointy standard Stanley phillips head screwdriver. Haven't seen a full set of Vessels like you describe though but I've only checked e-bay. Will look deeper into it.

Actually I'm not sure if I've got first gear sorted yet as it started to rain as I was finishing up. The clunk into first was pretty dramatic though as it was sitting on the centre stand. As soon as I get a chance I'll take it for a spin but it only seemed to happen after the 50km ride through the Adelaide Hills twisties so not sure if that "loosened" anything up after sitting for so many years or what. I haven't tried to "adjust" the clutch though. Not sure how to do it or what to adjust but I'm guessing there'd have to be an adjustment somewhere.

Edit: Just checked the manual and on page 1.16 is says in the first point;

1. All models are fitted with an hydraulic clutch for which there is no method of adjustment

So if my 1st gear selection issues remain I'll have to check back in with you guys for further suggestions.

Also ht manual keeps referring to "clutch fluid" not brake fluid. I assumed it's the same but we all know what assumptions are the mother of.

KiwiCol

😎  Always looking for the next corner.  😎

Hooli

The bad clunk is probably because you've changed the oil & all the oil that normally sits in the clutch plates came out. Until it's moved a bit it won't all get nicely between the plates again.

Then again they randomly do it, mine either goes in utterly smoothly or with a big clunk & there appears no logic to it.

SA14

Quote from: Hooli on Monday, 21 September  2020, 02:48 AM
The bad clunk is probably because you've changed the oil & all the oil that normally sits in the clutch plates came out. Until it's moved a bit it won't all get nicely between the plates again.

Then again they randomly do it, mine either goes in utterly smoothly or with a big clunk & there appears no logic to it.

Interesting. It's not "bad" as such, just that normal familiar clunk. I kind of like it. To me it serves as like a warning to hang on and get ready. But scattered showers all week so I might not get a chance to test ride until I get a decent break in the weather to go for a decent ride to see how it goes into first gear when the gears are hot.

Eric GSX1400K3

idle rpm affects it too, mine seems fine getting into 1st at 1000-1100rpm, a really big clunk any faster than that
I try to take one day at a time, however sometimes several days catch up with me at once.

SA14

Quote from: Eric GSX1400K3 on Monday, 21 September  2020, 08:17 PM
idle rpm affects it too, mine seems fine getting into 1st at 1000-1100rpm, a really big clunk any faster than that

Interesting, I'll check that. Thanks for the tip!

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