TigerTriple.com

Tiger Time => Steamers (1993-1998 Tigers) => Topic started by: Madruss on June 06, 2021, 04:28:28 AM

Title: Now to put it all back together
Post by: Madruss on June 06, 2021, 04:28:28 AM
I had only ridden this steamer for a test ride & a 50klm lap around where I live a couple of months ago.
To start, I found a bent righthand footpeg. So deciding to remove it & straighten the offending item, I discover the broken lower rear engine mounts.
Once the strip down commenced to remove the engine on one of these beasts you can open a can of worms. :icon_scratch: :icon_confused:
2. The forks showed an accumulation of dust around the gaiters, so there's a reseal job. Off to see Jim.
3. Removing the fairings, a screw/bolt attaching the fairing onto the fuel tank (Right Rear) failed to undo, hence slight "butcher job" to remove it, now the retaining plug turns, fuel tank leaks. So along with a couple of pieces of cracked fairing, off we go to a plastic welder in Toowoomba.
4. The instrument tube/bracket was broken. Found a handy young bloke who was good with TIG welder who repaired the item.
5. I was referred to a bloke who was just setting up his workshop 5klm from the regionally local (75klm away) bike shop (Jim) who specialised in Triumphs of all eras. 4 weeks later I had a message back the engine mounts were done. Thanks Marco
 
Title: Re: Now to put it all back together
Post by: ssevy on June 06, 2021, 04:43:13 AM
I had my tank welded with a special machine at a body shop, and it did not hold, as they used the wrong material.
I had it done a second time, and I believe it was nylon that they used, and it is still going strong.
I think I have a thread on here somewhere with the details?


Sent from my iPhone using Tapatalk
Title: Re: Now to put it all back together
Post by: Madruss on June 06, 2021, 05:45:47 AM
Don't know why my photo's came in sideways, the magnetic poles must  be shifting
Title: Re: Now to put it all back together
Post by: Sin_Tiger on June 06, 2021, 10:25:19 AM
This is looking like an interesting thread that we might learn a few things from. The engine mounts I've not seen before and it looks like a pretty good job in your other photos. You're lucky to have people with the skills to get the job done so close to you.

Don't worry we'll just  have a lie down to look at the photos, EXIF is something of a mystery  :tin hat
Title: Re: Now to put it all back together
Post by: Madruss on July 07, 2021, 10:21:04 PM
The engine mount bolts-- do the washer fit between the frame mounts & engine lower rear? Cant find any exploded diagrams anywhere
Title: Re: Now to put it all back together
Post by: Sin_Tiger on July 07, 2021, 11:27:30 PM
Flat washers go on the inside of the frame or engine plate as the fitted bolts are flanged Torx socket head. If memory serves me correctly the bolts are 10 12 x 1.25 thread (fine) so if they're badly rusted and you're replacing them or they're missing / chewed up, make sure you get a proper locking nut with the correct thread.

Correction above, my head is full of brake caliper sizes at the moment, that's what spending hours scraping salt out of caliper grooves does to your brain cells  :BangHead
Title: Re: Now to put it all back together
Post by: Sin_Tiger on July 08, 2021, 12:42:15 PM
Try the World of Triumph spares section.

This might help:- https://www.worldoftriumph.com/collections/100058905-0-2?type=tiger-885-carbs-upto-vin-71698 (https://www.worldoftriumph.com/collections/100058905-0-2?type=tiger-885-carbs-upto-vin-71698)
Title: Re: Now to put it all back together
Post by: Madruss on July 28, 2021, 04:49:38 AM
I had a look at the image but just shows parts, not where they fit precisely. I've measured the frame mounts & the engine mounts. They're a tight fit so it looks like a pain to reinstall  :icon_rolleyes:
Title: Re: Now to put it all back together
Post by: Madruss on July 29, 2021, 10:35:58 AM
Went to Total Tools today, purchased a 12mm hex head socket to loosen the swingarm bolts. Amazingly gave enough slop/movement to jiggle the engine back into place & throw a few bolts in.  :occasion14
Next thing to do is fit the the spacer washers, withdrawing one bolt at a time  ;)
Title: Re: Now to put it all back together
Post by: Sin_Tiger on July 29, 2021, 11:01:34 AM
You're not going to like me  :m but given what you're doing and the bike history in addition to your local conditions. I'd strongly recommend removing the swing arm when you're at this stage.

Two reasons, it's a lot easier to replace the chain rubbing strip with the swing arm off but most importantly the swing arm pivot bearings are the only bearings you cannot grease in situ, it has to come off and there's a good chance therefore that the grease will be the original.

If you go for it, take the pillion foot pegs off to give yourself better working access. Most importantly, pay very close attention to refitting the steel cups with seals correctly to prevent folding the seals over, do not just push them straight on, fit them over the spigot end at a slight angle with pressure on one side and the other side will just fall over.

Hold everything in place with a cable tie through each side until you've got the cups engaged between the supports before removing them.
Title: Re: Now to put it all back together
Post by: Madruss on July 29, 2021, 09:53:04 PM
I hear you but parts are 6-12 months or more wait down here. Bike has under 60k, not miles on the clock and the amount I'll get to ride it in these "Covid" restrictions, I'll take the risk & it'll go back together as is.
I ordered inlet rubbers ages ago, no sign of them. Backorder parts were 6 months behind delivery at the start of the "chinese pox" (Biological warfare) but that's another subject. So parts are another 12 months behind.
Title: Re: Now to put it all back together
Post by: Madruss on July 29, 2021, 09:54:59 PM
The chain slider is fine
Title: Re: Now to put it all back together
Post by: Sin_Tiger on July 29, 2021, 10:44:27 PM
I feel your pain but what I can't understand is why I can get stuff delivered in the UK from our "Communist Chums" in less than a week  :icon_scratch:

Worth having a look at Trevor's offerings https://www.triumphparts.co.uk/ (https://www.triumphparts.co.uk/) if you haven't already, competitive price and posts out very promptly.
Title: Re: Now to put it all back together
Post by: Beernard on July 30, 2021, 09:41:55 AM
Gday Madruss.
I'm down near Port Macquarie and don't have much helpful, accurate or useful advice. I just want to congratulate you on your solution to the question "How to swing a Steamer?". I have had some pretty wild versions myself!
You are in quite deep. Good on ya and all the best.
Regards, Bern.
Title: Re: Now to put it all back together
Post by: Bixxer Bob on August 02, 2021, 01:35:09 PM
Glad you're taking your time with the washers.  It's important to shim the gap between the engine and the frame mounting lugs correctly otherwise tightening the bolts stresses the lugs and can lead to cracks and failure (which I've seen on a couple of race bikes recently).

As for there being room to jiggle it around - there's a need to support and align the engine correctly and tighten engine bolts with care on the later 955s or you get vibrations.  IT may apply to Steamers too because I've just read the crash bar installation instructions for my Explorer and it even goes into doing swing arm adjustment afterwards.  That may, of course, be because of the shaft drive, but it's worth bearing in mind.
Title: Re: Now to put it all back together
Post by: Madruss on August 06, 2021, 12:52:19 PM
Progressing slowly. Remembering the reverse sequence ! Luck I bagged & tagged most bolts etc.
Title: Re: Now to put it all back together
Post by: London_Phil on August 06, 2021, 01:24:15 PM
Looking good
Title: Re: Now to put it all back together
Post by: Sin_Tiger on August 06, 2021, 11:48:13 PM
Coming along nicely  :new_popcornsmiley
Title: Re: Now to put it all back together
Post by: gcloys on May 12, 2022, 07:38:08 PM
Quote from: ssevy on June 06, 2021, 04:43:13 AMI had my tank welded with a special machine at a body shop, and it did not hold, as they used the wrong material.
I had it done a second time, and I believe it was nylon that they used, and it is still going strong.
I think I have a thread on here somewhere with the details?


Sent from my iPhone using Tapatalk
So glad I stumbled on this post.  There was no follow up to your initial post.  As a newbie owner but familiar with plastic tank woes from my Cagiva Gran Canyon, I'm happy to hear it worked well and is STILL working well.  Drader injection tool at precisely the correct temp and matching material I hope will solve any problems I may have in the future with my '98.
Title: Re: Now to put it all back together
Post by: ssevy on May 12, 2022, 09:13:38 PM
Mine is still tight as a crab's ass ( and that's watertight )


Sent from my iPhone using Tapatalk
Title: Re: Now to put it all back together
Post by: Sin_Tiger on May 16, 2022, 01:54:24 AM
Make sure the drain tube from the filler surround is clear. The screw in alloy ferrule often gets furred up and fine debris builds up in the tube. If it is blocked take great care trying to clear it as it's all plastic inside the tank. Blow from the bottom up. Check the filler is getting a good seal on the steel ring as they often rust.
Title: Re: Now to put it all back together
Post by: gcloys on May 31, 2022, 12:04:09 AM
Quote from: Sin_Tiger on May 16, 2022, 01:54:24 AMMake sure the drain tube from the filler surround is clear. The screw in alloy ferrule often gets furred up and fine debris builds up in the tube. If it is blocked take great care trying to clear it as it's all plastic inside the tank. Blow from the bottom up. Check the filler is getting a good seal on the steel ring as they often rust.
Thanks for this advice. If this is the breather tube you're referring to then mine was clear when I blew from the bottom up with just breath.
Title: Re: Now to put it all back together
Post by: Sin_Tiger on June 04, 2022, 01:04:50 AM
That's good news, worth checking from time to time.
Title: Re: Now to put it all back together
Post by: Madruss on August 10, 2022, 01:38:24 PM
The tiger has been on the back burner for too long. Had an injury which prevented me for bending over to work on the bike, then a new job too.
Well got a week in the sin bin (covid enforced isolation) so focus is the tiger. 
Filled the engine oil & coolant but had to drain the coolant back out as the water pump was leaking.
Re did the water pump gasket/seal tonight, so tomorrow, as the USA servicemen would say "fire in the hole"
Title: Re: Now to put it all back together
Post by: Madruss on August 10, 2022, 01:51:07 PM
Got a bit keen yesterday to fabricate some footpeg extensions. Built a similar set out of stainless for my Tenere before.
Only had some 3mm mild steel this time but now have a new gasless MIG which I thought needed a run.
Title: Re: Now to put it all back together
Post by: Madruss on August 10, 2022, 01:54:28 PM
Thanks  :icon_salut:
Title: Re: Now to put it all back together
Post by: Madruss on August 10, 2022, 02:30:05 PM
Had the battery hooked up to see what lights required bulb replacement before refitting body panels etc.
All the instrument lights bulbs were shot, (as I remembered on my last ride) one tail light bulb aswell. One indicator bulb only required a clean as corrosion was stopping it from earthing & working.
Title: Re: Now to put it all back together
Post by: Sin_Tiger on August 10, 2022, 10:43:29 PM
Nice job on the foot pegs, you'd have to look closely to see it wasn't stock  :thumbsup

I just replace all the idiot and back lights with LED's (except the low fuel) now that I can get a complete & correct set from LightenUpgrade delivered for £20, helpful chap is Mark.
Title: Re: Now to put it all back together
Post by: Madruss on August 11, 2022, 01:53:06 AM
Sunny winter morning in OZ [attach id=18416]tiger 11 0822.jp]
Title: Re: Now to put it all back together
Post by: Madruss on August 11, 2022, 11:26:45 AM
Well it's finally running
Title: Re: Now to put it all back together
Post by: ssevy on August 11, 2022, 05:36:07 PM
 :><
Title: Re: Now to put it all back together
Post by: Sin_Tiger on August 11, 2022, 06:58:29 PM
 :wings
Title: Re: Now to put it all back together
Post by: Madruss on August 12, 2022, 12:38:17 AM
Took a video of the start up but can't transfer it from my phone.
The oil warning light doesn't come on before start or after stop either. :icon_confused: 
Checking wiring, maybe replace the sensor unit. Looks like a standard old Ford or Chrysler engine sensor to me
Title: Re: Now to put it all back together
Post by: Madruss on August 13, 2022, 05:57:27 AM
Hopefully the last few bits n pieces[attach id=18426]
Title: Re: Now to put it all back together
Post by: Madruss on August 13, 2022, 05:58:21 AM
Why am I getting two images ?
Title: Re: Now to put it all back together
Post by: Madruss on August 13, 2022, 10:03:35 AM
Just finished fitting the low oil pressure warning light, ignition on engine not running, light illuminated. Engine running, light off  :icon_biggrin:
All the warning lights now fully operational, temperature gauge working. Headlight, indicators, tail lights, horn etc all good.

My little garden shed had some fumes & noise eminating from it this afternoon (much to my enjoyment)
Not too far away now, time to put miles under the wheels  :><
Title: Re: Now to put it all back together
Post by: Lee337 on August 15, 2022, 11:38:53 AM
 :><
Title: Re: Now to put it all back together
Post by: Sin_Tiger on August 15, 2022, 04:53:31 PM
Worth checking the fan switch before you go far  ;)
Title: Re: Now to put it all back together
Post by: Madruss on August 16, 2022, 11:25:25 AM
Thanks. Another thing to check  :bowdown
Been thinking of what else to check before refitting the bodywork !
Looking through the manual, I can't any reference to checking the thermo fan actuation. Been a couple of years since I've had to go deep into diagnostics  :icon_eek: 
Title: Re: Now to put it all back together
Post by: gcloys on August 16, 2022, 07:21:19 PM
Quote from: Madruss on August 16, 2022, 11:25:25 AMThanks. Another thing to check  :bowdown
Been thinking of what else to check before refitting the bodywork !
Looking through the manual, I can't any reference to checking the thermo fan actuation. Been a couple of years since I've had to go deep into diagnostics  :icon_eek: 
Be one with the bodywork. When I'm feeling Zen, I go undo and redo all the fasteners for time. With my eyes closed, only by feel. Now it's like a tea ritual for me. :rock-1:
Title: Re: Now to put it all back together
Post by: Sin_Tiger on August 18, 2022, 12:47:40 AM
Quote from: gcloys on August 16, 2022, 07:21:19 PMBe one with the bodywork. When I'm feeling Zen, I go undo and redo all the fasteners for time. With my eyes closed, only by feel. Now it's like a tea ritual for me. :rock-1:

 :ImaPoser  :thumbsup

First short out the wires connected to the switch to check that the fan is working. There's no easy way to check the switch as the set point is 105 C, easiest just to let it idle until the fan cuts in and check the gauge hasn't gone past half way.
Title: Re: Now to put it all back together
Post by: Madruss on August 21, 2022, 01:51:29 AM
Here's some plastic cowlings found in the top box I have no idea where they fit.
The previous owner found them in the top box when he bought it & he didn't know either
Are they necessary ?
It's hot out here in Oz, so my thinking is Unecessary
Title: Re: Now to put it all back together
Post by: Lee337 on August 21, 2022, 11:44:23 AM
Not sure about older tigers as mine's an 06 model, but I have similar bits of plastic on my '93 Trophy. They go under the tank and over the cylinder head. I guess it's a kind of heat shield as it keeps some of the heat from the cylinder head away from the coil packs.

In the 2nd photo you can see a foam bit. This is pretty much where the plastic heat shield meets the cylinder head. The cut outs in the foam are for the plug leads, clutch and throttle cable to pass through.

I doubt it does much for keeping the heat off the unbderside of the tank as there's usually a heat shield stuck on the bottom of the tank, so I'd guess it's only function id to stop the coul packs overheating.
Title: Re: Now to put it all back together
Post by: Madruss on August 21, 2022, 08:57:18 PM
Ahh Ok. :bowdown I can understand now.
I always wondered what the tube across the frame was there to support. :><
Title: Re: Now to put it all back together
Post by: Sin_Tiger on August 21, 2022, 09:36:45 PM
There should be rubber ends on the tubes for the tank to sit on. Cowls fit as per Lee's photo and the same as T300's. Not sure if it makes any difference to the cooling but they will deflect hot air away from the tank, coils and rider.

I had them fitted on my Singapore Steamer, never had an issue with it getting hot.
Title: Re: Now to put it all back together
Post by: Madruss on August 22, 2022, 11:36:12 AM
I'll need to have a look in the parts box for the rubber stoppers
Can't remember ever seeing them in the strip down either. The shrouds were never in position for the previous 2 owners to me  :icon_confused:
I'd reckon the only reason they weren't turfed away as they had Triumph on them  ;) 
Title: Re: Now to put it all back together
Post by: Sin_Tiger on August 22, 2022, 01:17:56 PM
Crutch end stop rubbers, chair / table leg protectors, bit's of rubber hose or if you know anyone with a 3D printer, print them with flexible filament  :bad

Really should be there to stop the metal ends rubbing against the tank nylon, especially with the temps you guys get  :XXsunsmile
Title: Re: Now to put it all back together
Post by: Madruss on August 23, 2022, 10:00:10 AM
Quote from: Sin_Tiger on August 22, 2022, 01:17:56 PMCrutch end stop rubbers, chair / table leg protectors, bit's of rubber hose or if you know anyone with a 3D printer, print them with flexible filament  :bad

Really should be there to stop the metal ends rubbing against the tank nylon, especially with the temps you guys get  :XXsunsmile
That was along my line of thinking. :thumbsup
I'm pretty sure they weren't in place when I stripped it down, especially being owner # 5  :icon_redface
:
Title: Re: Now to put it all back together
Post by: Madruss on September 27, 2022, 11:14:00 AM
Found a length of radiator hose which is a good tight fit over mounts, hope it isn't too thick.
Left my phone/camera out in the machine at work so not photo today.
Title: Re: Now to put it all back together
Post by: Madruss on October 09, 2022, 01:18:05 AM
Well, I found one, so an old piece of heater hose is similar in size !
Title: Re: Now to put it all back together
Post by: Lee337 on October 09, 2022, 11:34:54 AM
Looks like that'd do the job nicely.  :><
Title: Re: Now to put it all back together
Post by: Madruss on October 09, 2022, 11:53:32 AM
Well lucky me found the other plug on the back of the bench.
Now the JB "marine weld" has set & sealed the tank leak, I can continue the reassembly  :thumbsup
Title: Re: Now to put it all back together
Post by: Madruss on October 09, 2022, 12:10:50 PM
As I'm getting closer to a finished product, I now see the handlebars look bent lower on the righthand side :icon_sad: 
The bike, I was told fell over in a shipping container while in storage but I'm pretty sure that was a :Topes  story  :icon_frown:
So I'll be in search  :icon_study:  of another set of bars.
While I'm there, I'll try to track down an upholsterer, to fill the dip in the seat being a 190cm tall rider !
Title: Re: Now to put it all back together
Post by: Sin_Tiger on October 09, 2022, 05:16:47 PM
Good progress  :thumbsup 

If you need measurements, let me know, I have a spare straight bar, as you do  :icon_rolleyes:
Title: Re: Now to put it all back together
Post by: Madruss on October 14, 2022, 09:50:26 PM
I took some measurements of the handlebars, several actually, to make sure it wasn't an optical illusion.
appears the righthand side is 15mm down & 15mm pushed back.
Also, I repaired the tube type bracket which holds the fairing & instrument cluster, it was broken directly below the  tachometer.
Where this bracket mounts onto the frame, should it come straight forward? It appears to be aiming to the left when sitting on the bike.  :icon_confused:
Title: Re: Now to put it all back together
Post by: Madruss on October 15, 2022, 10:34:23 AM
My repair to the fairing bracket.
Looks straight from the front. Second guessing repairs from over 12 months ago
Title: Re: Now to put it all back together
Post by: Lee337 on October 15, 2022, 02:55:08 PM
Are we nearly there yet?  :icon_mrgreen:
Title: Re: Now to put it all back together
Post by: Sin_Tiger on October 15, 2022, 06:05:52 PM
The stay to the headstock should be dead straight ahead.
Title: Re: Now to put it all back together
Post by: Madruss on October 15, 2022, 10:02:13 PM
As the bike must have fallen on the righthand side thus pushing brackets etc to the left.
I'll see how the fairing connects up to the tank & the headlight area.
Isn't a pretty beast  :icon_neutral: , with it's fair share of battle scars & me being the 5th owner
Title: Re: Now to put it all back together
Post by: Madruss on October 16, 2022, 11:42:25 AM
This'll be a Bob the Builder theme repair " Can he fix it"  :icon_lol: or buy another set.
Title: Re: Now to put it all back together
Post by: Madruss on October 18, 2022, 12:08:21 PM
Well the bars are a bit more heavy duty than I'd imagined.  :icon_rolleyes:
I'll look for some replacements
Title: Re: Now to put it all back together
Post by: Sin_Tiger on October 18, 2022, 11:29:15 PM
I suspect a lot of replacements will be thinner wall than the original  :icon_sad:
Title: Re: Now to put it all back together
Post by: Madruss on October 19, 2022, 12:56:39 PM
Gleaned some information from a workmates son (welder/boilermaker) who suggested applying a moderate heat, carefully then work it slowly, taking care of the final alignment.  :icon_study:
Will give it a go tomorrow arvo 
Title: Re: Now to put it all back together
Post by: Sin_Tiger on October 19, 2022, 10:31:48 PM
Keep the torch moving all around and don't let it get more than dull cherry red. Use a longer tube over the bar end to give you more control rather than hitting it  :nono
Title: Re: Now to put it all back together
Post by: Madruss on October 20, 2022, 12:22:14 PM
We've got it halfway there today.
Definitely no old "Harley style" mechanical repair going on heavy dull instruments  :icon_lol: 
Title: Re: Now to put it all back together
Post by: London_Phil on October 20, 2022, 04:43:52 PM
Quote from: Madruss on October 20, 2022, 12:22:14 PMWe've got it halfway there today.
Definitely no old "Harley style" mechanical repair going on heavy dull instruments  :icon_lol: 
As the owner of an old Harley, I resemble that remark....
Title: Re: Now to put it all back together
Post by: Madruss on October 20, 2022, 10:03:26 PM
Quote from: London_Phil on October 20, 2022, 04:43:52 PMAs the owner of an old Harley, I resemble that remark....
So it's not a cold chisel & a 2 lb hammer as I was lead to believe  :rfl
Title: Re: Now to put it all back together
Post by: Beernard on October 21, 2022, 10:30:31 AM
Gday Russ,

First up, I love "fixing". Not good at it myself, but it may be worth contemplating "replacing". My bars got bent and I was led into the world of "maybe there's something better". Personal choice, but the originals were too low and too swept for me. I ended up with a combination of 1" risers and motocross bars that are higher, flatter and more forward. Suits me. There is a thread about these somewhere here. As I say, suits me. Not everyone, for sure. I am just south of Port Macquarie, drop in if you are going by. More importantly, all the best in your efforts with one of these great bikes. All the best.

Bern.
Title: Re: Now to put it all back together
Post by: Madruss on October 21, 2022, 11:09:58 AM
Yes, been in 2 minds of which way to go.
Grabbed my neighbor/cousins butane torch in his shed & had a go yesterday, realigning to within 5mm.
Continued again this afternoon with success within "tolerance"  :thumbsup
As my dear departed Mum would say "galloping horses won't notice it"  ;)
A quick rub with emery tape & a coat of satin black, once dry ready to re assemble in the morning.
Was thinking of attending the motorcycle only Swap-meet at Laidley Qld run by the Historic Motorcycle Club of Queensland but a high percentage extensive rainfall, I'll wait till i hear a weather report in the morning
Title: Re: Now to put it all back together
Post by: Madruss on October 22, 2022, 01:25:01 AM
Not always sunny here
Title: Re: Now to put it all back together
Post by: Madruss on October 22, 2022, 01:31:28 AM
My shed is so small I have to step outside to change my mind
Title: Re: Now to put it all back together
Post by: Madruss on October 22, 2022, 11:35:55 AM
As the jobs dwindle down & before I refit the fairing & screen, I thought "how long since the brake have been bled " :icon_confused:
Removing the master cylinder cap was a challenge :BangHead
Employing an impact screwdriver (a neccesity when you worked a '70s Honda) wasn't a success untill heat from a hair dryer around the outside gave some joy. One released but the other just wouldn't have any part of it. :icon_sad:
Drilling the countersunk top of the screw out of the lid was the next successful step to remove the cap. Tiny aligator style vice grips assissted with removal of the remainder of the screw.  :icon_biggrin:
The opaque nature of the fluid made my assessment correct with regard to service history.
A thorough bleeding of both calipers gave me a sense safety for the first trip. 
Title: Re: Now to put it all back together
Post by: Madruss on October 22, 2022, 01:13:14 PM
I could see an ooze of fuel around my recent repair on the tank, so off it came once more to investigate. Removing the tank once I found an area which I had previously spread JB weld required some attention around threaded insert.
Fingers crossed this timeJB glue.jpg
Title: Re: Now to put it all back together
Post by: London_Phil on October 22, 2022, 02:31:29 PM
Quote from: Madruss on October 22, 2022, 01:13:14 PMI could see an ooze of fuel around my recent repair on the tank, so off it came once more to investigate. Removing the tank once I found an area which I had previously spread JB weld required some attention around threaded insert.
Fingers crossed this timeJB glue.jpg

I've posted before about the very small margin of error available on those tank fitments.
Many years ago, I bought a crash damaged tank and cut it open. I think I posted them on the forum, but there is a very small amount of plastic surrounding the captive nuts. Proceed with caution...
In fact, look at my profile pic for the ones at the fuel tank...
Title: Re: Now to put it all back together
Post by: Sin_Tiger on October 22, 2022, 07:25:12 PM
If master cylinder screws don't come out without a fight, I just take the master cylinder off the bars, here's how I look at it:-

If I haven't changed the fluid and the screws are tight, God know when it was last done, so I'm going to be into a complete strip down as the piston boot will almost certainly be toast anyway.
Taking anything heavier than a JIS screwdriver to them while they are on the bars is asking for trouble. If I get frustrated a big hammer is my calming tool and that means a real risk of bending the bars.
The cylinder is not flat and level, so trying to even get a square whack at it hard enough and guaranteed the bars will move with the risk of damage that poses.
Trying to drill out a screw in alloy is not easy at the best of times, on wobbly bars and at odd angles just make it harder and there's always the risk of getting fine swarf in the fluid which will gravitate straight into the piston / bore.

Not trying to lecture anyone, just explaining my internal risk assessment process.  :^_^
Title: Re: Now to put it all back together
Post by: Madruss on October 22, 2022, 11:57:03 PM
Yes, it was a tricky job drilling the countersunk head off the screw, :icon_rolleyes:  whilst still in situ on the master cylinder.
Numerous changes of drill bits, even resorting to my only reverse taper bit aswell. I Only went slighty off vertical, removing a minimal amount of alloy in the cap. :icon_eek:
What really made me  :icon_redface: was how easy the damn screw came out of the cylinder after all the fight it put up  :icon_frown:
After just straightening that side of the bars, I had no intention of employing anything bigger than the impact screwdriver & "my soft blow hammer" in the process  :nono 
Title: Re: Now to put it all back together
Post by: Madruss on October 23, 2022, 09:00:31 AM
Getting to the end now.
Found this in the top box. Can't remember removing it, so should there be 2  :^_^
Title: Re: Now to put it all back together
Post by: Madruss on October 23, 2022, 10:21:14 AM
Nearly there
Title: Re: Now to put it all back together
Post by: London_Phil on October 23, 2022, 10:25:39 AM
Quote from: Madruss on October 23, 2022, 09:00:31 AMGetting to the end now.
Found this in the top box. Can't remember removing it, so should there be 2  :^_^

Nope, it the cover between the alternator and cylinders, to hide the nest of piping.
Title: Re: Now to put it all back together
Post by: Madruss on October 23, 2022, 11:37:13 AM
Quote from: London_Phil on October 23, 2022, 10:25:39 AMNope, it the cover between the alternator and cylinders, to hide the nest of piping.
Thanks, I had no idea where it would fit.
Being the 5th owner I've found a few "deleted" items along the way, with several "dodgey" fasteners around this bike. :icon_eek:
Title: Re: Now to put it all back together
Post by: Madruss on October 23, 2022, 12:14:23 PM
Quote from: London_Phil on October 23, 2022, 10:25:39 AMNope, it the cover between the alternator and cylinders, to hide the nest of piping.
Thanks, I had no idea where it would fit.
Just went to have a look, I probably removed it but that was over 12 months ago from when I started  :icon_rolleyes: 
Being the 5th owner I've found a few "deleted" items along the way, with several "dodgey" fasteners around this bike. :icon_eek:
Title: Re: Now to put it all back together
Post by: Madruss on January 11, 2023, 12:00:53 PM
Well, I'd stalled out on the job for a few months as some house projects before Christmas required attention.
In the meantime, I'd been conversing with a fellow tiger owner in north Qld about going halves in another tiger to split up the parts but in the end, I'm buying the other blokes '94 tiger he'd given up on.
Freight from the very top of the Barrier Reef to here was going to be over half the negotiated price  :icon_eek:
I went through my old contact list & found an owner operator bike transporter, I'd used previously, who could move the tiger a week earlier than the "big company", over $100 less & will do door to door.  :thumbsup 

I'll put some photo's up when it arrives.
The plan is to keep the accessories, the unbuckled front wheel, the new battery & re upholster/repad the seat (increase the seat to footpeg distance) to suit my long legs.
The rest of the bike & my seat can go to a swapmeet for someone else to do whatever, hopefully cover my costs giving me some parts for free  :occasion14 
Title: Re: Now to put it all back together
Post by: Lee337 on January 11, 2023, 06:11:36 PM
Be very careful having more than one Triumph in your workshop, that's how it started for me.

One Tiger, then another Tiger, then a Trophy, then Tiger2 left to help pay for the Trophy, then a Daytona turned up and now another Tiger.

3 years ago I only had one Honda  :bug_eye

 :wheel
Title: Re: Now to put it all back together
Post by: Madruss on January 11, 2023, 09:46:37 PM
It'll be a tight squeeze into a 4.5m x 3m garden shed. :icon_frown:
I'll have to be like the local bike shops who move their stock outside to use their workshop!
Mrs M isn't impressed now  :nono so a larger shed is in the planning stages  :icon_biggrin:
Title: Re: Now to put it all back together
Post by: Sin_Tiger on January 11, 2023, 11:32:57 PM
I have a mate who lives by that philosophy, although he'll deny it.

Just build another shed  :icon_lol: on teh plus side, you'll have more hiding places  :icon_mrgreen:
Title: Re: Now to put it all back together
Post by: ssevy on January 12, 2023, 05:09:26 PM
Quote from: Madruss on October 22, 2022, 11:57:03 PMYes, it was a tricky job drilling the countersunk head off the screw, :icon_rolleyes:  whilst still in situ on the master cylinder.
Numerous changes of drill bits, even resorting to my only reverse taper bit aswell. I Only went slighty off vertical, removing a minimal amount of alloy in the cap. :icon_eek:
What really made me  :icon_redface: was how easy the damn screw came out of the cylinder after all the fight it put up  :icon_frown:
After just straightening that side of the bars, I had no intention of employing anything bigger than the impact screwdriver & "my soft blow hammer" in the process  :nono 

I had a factory screw stuck on my Legend master cylinder cover, and I used a lefthand threaded drill bit to gently remove the head. The galling seems to take place on the shoulder of the head and not the threads, as mine also unscrewed easily once the head was free.
Since that day, I have purchased JIS screwdrivers, as they are not Philips screws, and I use just a dab of grinding compound on the tip of the screwdriver, and tap it with a hammer to seat it snugly before trying to turn those screws out.
A thin film of red rubber grease (brake fluid safe) can be applied to the shoulder of the screw before replacing it, and this also helps reduce the galling effect of the dissimilar metals.
Title: Re: Now to put it all back together
Post by: Lee337 on January 13, 2023, 01:08:26 PM
+1 for the JIS screwdrivers. My brother bought me a set for Xmas in 2021. worth their weight in gold as far as I'm concerned. A local bike Journo recommended them to me when he came to do a piece on rebuilding Tabitha Trophy.

Used regularly when working on both Tallulah and Daysie - not had a stripped head since using them yet, whereas when working on Tabitha, I ended up having to drill out the screws for both front brake and clutch reservoir caps as well as many other screws.
Title: Re: Now to put it all back together
Post by: Madruss on January 14, 2023, 03:36:51 AM
Yes I've discovered "the tap on the head treatment" had been a good starting point for many cantackerous bolts & nuts.
Years ago I was snookered trying to loosen large nut 2" on my Cat motor grader.
A 3/4 drive socket T bar & a length of pipe wouldn't budge it.
A very experienced machine shop bloke advised me to spend some with a hammer running around each face. The "shock treatment" broke the slight corrosion which was acting like "loctite"
A lesson learned  :notworthy
 
Title: Re: Now to put it all back together
Post by: Madruss on January 20, 2023, 12:13:10 PM
Quote from: Madruss on January 11, 2023, 12:00:53 PMWell, I'd stalled out on the job for a few months as some house projects before Christmas required attention.
In the meantime, I'd been conversing with a fellow tiger owner in north Qld about going halves in another tiger to split up the parts but in the end, I'm buying the other blokes '94 tiger he'd given up on.
Freight from the very top of the Barrier Reef to here was going to be over half the negotiated price  :icon_eek:
I went through my old contact list & found an owner operator bike transporter, I'd used previously, who could move the tiger a week earlier than the "big company", over $100 less & will do door to door.  :thumbsup 

I'll put some photo's up when it arrives.
The plan is to keep the accessories, the unbuckled front wheel, the new battery & re upholster/repad the seat (increase the seat to footpeg distance) to suit my long legs.
The rest of the bike & my seat can go to a swapmeet for someone else to do whatever, hopefully cover my costs giving me some parts for free  :occasion14 


The big rain (massive flooding) event has stopped traffic movements, so where the #2 tigers whereabouts are   :^_^   
Title: Re: Now to put it all back together
Post by: Sin_Tiger on January 21, 2023, 04:43:15 PM
If the engine's oil tight it should fine  ;)
Title: Re: Now to put it all back together
Post by: ghulst on January 28, 2023, 11:22:07 AM
Nice work Madruss. Hope your Tiger in the wild has been recovered now? My first Tiger was bought out of an inheritance and after purchasing the bike, I found an old ad in the manual for a Tiger with accident damage. It didn't take me long to figure out that was mine. The speedo bucked seemed to have been recreated completely out of putty.  :icon_lol: So, I also had to recreate the whole front part of the bike that holds the lights and the fairing. Fortunately my bars were straight though.
Hope the parts bike is coming in soon.

Quote from: Lee337 on January 11, 2023, 06:11:36 PM3 years ago I only had one Honda

Good to see you came to your senses. ;)

Quote from: Madruss on January 11, 2023, 09:46:37 PMMrs M isn't impressed now  :nono so a larger shed is in the planning stages  :icon_biggrin:

Wish I had the space for that... And the planning permission options. 
Title: Re: Now to put it all back together
Post by: Madruss on February 04, 2023, 12:17:39 PM
It's arrived, albeit a couple of weeks late.
The carrier's trailer suffered a misadventure the day following loading, which required major repairs, hence the delay.
Title: Re: Now to put it all back together
Post by: Madruss on February 04, 2023, 12:25:37 PM
The next issue to address is, the keys went "walkabout" before loading  :icon_eek:
How do I go about opening the seat to access the new battery to fit into the black bike without damage. :^_^ 
Title: Re: Now to put it all back together
Post by: Madruss on February 05, 2023, 10:49:55 AM
Had a win on my initial inspection with brand name crashbars
Title: Re: Now to put it all back together
Post by: Madruss on February 05, 2023, 10:53:49 AM
Unknown brand pannier racks but brand name mufflers which are a bit big (melted the sidecovers)
Title: Re: Now to put it all back together
Post by: Madruss on February 05, 2023, 11:08:18 AM
Variation of discs from '94 to 96
Title: Re: Now to put it all back together
Post by: Sin_Tiger on February 06, 2023, 01:08:12 AM
The "skinny" discs are aftermarket. I've used both of those on Steamers and couldn't say there was a lot of difference in performance, except the skinny ones rusted faster, lower silicone steel.
Title: Re: Now to put it all back together
Post by: Beernard on February 06, 2023, 08:16:56 AM
Nice work Russ. Looks like you have picked up some nice bits as well as all the other stuff on a pretty complete bike. Good on ya!
Title: Re: Now to put it all back together
Post by: Madruss on February 06, 2023, 10:25:22 AM
Quote from: Beernard on February 06, 2023, 08:16:56 AMNice work Russ. Looks like you have picked up some nice bits as well as all the other stuff on a pretty complete bike. Good on ya!
Thanks Beernard  :occasion14
My righthand footpeg mounting in bent so that'll be another swap out.
I can't see the yellow brakelines fitting in to the black colour scheme either, so they'll stay.
I'll have the seat repadded "taller" with a different fabric too & put my seat with the primer/calypso tiger!
Title: Re: Now to put it all back together
Post by: Madruss on February 06, 2023, 12:51:36 PM
The compliance plate is in a rather weird location, out on the swingarm, near the pillion footpeg  :^_^ 
Title: Re: Now to put it all back together
Post by: Madruss on February 11, 2023, 01:27:24 PM
I needed to gain access to the battery on the 92 but without keys  :^_^ I removed the seat from the 96, the conventional way (with a key) noting the cable to the seat release :icon_idea:
I found after removing the pannier racks, plus exhaust I could lever up the seat using a long screwdriver & then another long one, push the cabled release mechanism to pop the seat off :occasion14
Access to the battery successful, so now is on charge. Hopefully, by morning, it'll be fully charged.
Title: Re: Now to put it all back together
Post by: Madruss on February 11, 2023, 01:30:02 PM
More photos
Title: Re: Now to put it all back together
Post by: ghulst on February 11, 2023, 03:07:49 PM
Was the key not included in the deal?
Title: Re: Now to put it all back together
Post by: Madruss on February 12, 2023, 01:32:54 AM
Unfortunately the owner had the bike strapped to a bike crate on the back of his truck, with the keys in the ignition!
Some "opportunist thief" grabbed them 😰😬
Title: Re: Now to put it all back together
Post by: Madruss on February 12, 2023, 01:38:56 AM
I intend to remove the seat lock mechanism with the lock barrel & take it to a locksmith I've used in town & have a key  made to suit.
A bit of a pain in mule/donkey (being polite as we don't have an emoji of an Ass)  :icon_smile:
Title: Re: Now to put it all back together
Post by: Beernard on February 12, 2023, 10:20:46 AM
Gday Russ.
Its quite a few years ago, I have relatively no memory left, but I have been down this road (I think!). Please check this. I had a key cut but the locksmith explained that the seat lock was shorter than the ignition lock (he's a biker). I took it home anyway (of course!) but it didn't work in the ignition. Could be the locksmith didn't have a clue, but this was my experience. My homework was the pain of removing the ignition switch. I wonder now if I could have taken the whole bike in and had the locksmith do his magic? I also suppose there are locksmiths and then there are locksmiths!
I hope my memory is as bad as I suspect, and you have a win. If my experience proves correct (dubious!), I think the "whole bike to the shop" may be a less painful option, if possible.
This is a bit gnarly, but in good faith. Worth a question and maybe saves you some time.
Regards,
Title: Re: Now to put it all back together
Post by: Madruss on February 12, 2023, 10:35:59 AM
I was thinking of going down that pathway Beernard, if worse comes to worse.
A fairly knowledgeable motorcycling relative of mine suggested a certain locksmith in the city, who is a motorcyclist (that's a bonus) has the knowledge to cut keys on the VIN #
So, here's hoping  :^_^
Title: Re: Now to put it all back together
Post by: Sin_Tiger on February 12, 2023, 03:20:48 PM
Quote from: Beernard on February 12, 2023, 10:20:46 AMI hope my memory is as bad as I suspect, and you have a win. If my experience proves correct (dubious!), I think the "whole bike to the shop" may be a less painful option, if possible.

Good news, your memory isn't as suspect as you think. If I remember correctly, there are 5 wafers in the ignition lock barrel and only three in the tank and seat and panniers if you have them.

A decent locksmith should be able to get the coding for a cut, there's a lot of fancy tools out there nowadays.
Title: Re: Now to put it all back together
Post by: Madruss on February 13, 2023, 10:26:36 AM
Quote from: Sin_Tiger on February 12, 2023, 03:20:48 PMIf I remeber correctly, there are 5 wafers in the ignition lock barrel and only three in the tank and seat and panniers if you have them.

A decent locksmith should be able to get the coding for a cut, there's a lot of fancy tools out there nowadays.

Great information on here, the best place to gain "the knowleadge"
Title: Re: Now to put it all back together
Post by: ghulst on February 16, 2023, 10:20:55 PM
Wouldn't Triumph be able to do something if you provide them with the VIN?
Title: Re: Now to put it all back together
Post by: Madruss on February 17, 2023, 10:35:36 AM
Closest Triumph Dealer is 170klm away  :^_^
I've never dealt with them either!
How to prove ownership, long distance too.
 I've heard of some suspect characters spinning some "Grimms fairy tale" stories to gain access to property, so I'll have to try to contact the one in Brisbane Qld to see how to go about it.

Title: Now to put it all back together
Post by: ghulst on February 17, 2023, 09:25:40 PM
I'd at least take a shot at it. ;)
Title: Re: Now to put it all back together
Post by: Sin_Tiger on February 18, 2023, 01:16:35 AM
Memory not as good as I thought. Tank barrel (not pictured) has 5 wafers + a retention slide. I think the attached was an ignition barrel but I forgot to change the file name  :icon_rolleyes:

Don't know if these will be of any help.

Tip, if you decide on taking a lock apart and haven't done it before, do it with your hands and the parts inside a big clear plastic bag.  :nod
Title: Re: Now to put it all back together
Post by: Madruss on February 20, 2023, 08:07:09 PM
I've had some key barrel stuff in pieces previously,  :^_^
Also a transmission controller with multiple microswitches out my old motor grader :BangHead
Thanks for the insight but I'll go to the locksmith armed with the VIn # & hope for the best  :occasion14
Title: Re: Now to put it all back together
Post by: Madruss on March 11, 2023, 07:06:02 AM
Found what I thought were a pair of mirrors but ended up being two lefts.  :icon_redface:
So, after digging through the "scrap pile" of handy bits, I managed to build a righthand mirror
Title: Re: Now to put it all back together
Post by: Sin_Tiger on March 11, 2023, 09:20:50 PM
I prefer to stick with the round originals, they work well for me and if you smack one on a trip they can be swapped not being handed.
Title: Re: Now to put it all back together
Post by: Madruss on March 11, 2023, 10:30:29 PM
For $5 au the pair  :m  :thumbsup
Title: Re: Now to put it all back together
Post by: Madruss on March 11, 2023, 11:52:42 PM
Currently (Sunday morning down in OZ) in the process of transferring the HB crashbars from the Calyso blue'92 to the black 94.
I noticed, what appears to be an oil balancer/crossover pipe around the oil filter on the 92. It appears to be deleted on the 94.
Any ideas  :^_^ [attach id=18828]
Title: Re: Now to put it all back together
Post by: Madruss on March 12, 2023, 10:45:36 AM
Quote from: Sin_Tiger on March 11, 2023, 09:20:50 PMI prefer to stick with the round originals, they work well for me and if you smack one on a trip they can be swapped not being handed.
Fair enough, the only ones I had were after market chrome japanese "will fits"
I liked '80's Kawasaki style black ones so these were as close to them
Title: Re: Now to put it all back together
Post by: Sin_Tiger on March 13, 2023, 02:37:49 PM
I'm not 100% certain but I believe it's an external oil cooler bypass link, the later engines had them internally.

While you're on your hands and knees  :augie  it's worth the effort to take the sump off and give everything a good clean, you'll be surprised how mucky it'll be. You'll be changing the oil and filter no doubt so it's not a lot of extra work, the only tricky bit is getting the rear middle screw out, as it sits above the exhaust cross over.

Check the state of the oil pressure switch cable / connector, they have a hard life, it might be worth making a short link wire with a more accessible / protected connector.
Title: Re: Now to put it all back together
Post by: Madruss on March 14, 2023, 09:57:27 AM
Ok,
Just had fresh oil in & a ten minute run, so I might run it for longer, then another change as it hasn't been out on the road coming up for 2 years.
Title: Re: Now to put it all back together
Post by: Madruss on March 14, 2023, 10:10:51 AM
The Hepco Becker bars, I'd rather call them "brush bars" than crash bars, have taken a lot more time than I'd envisaged :icon_redface:
I found there removal from the Calyso donor bike was rather easy without the airbox in the way.
Stripping all the fairing etc back off the black bike made me feel  :BangHead 
The top left rear engine mount bolt was "fun" remove, the nut inparticular was  :icon_frown: Anyway the bars are 90% together apart from the front cross bar.
Title: Re: Now to put it all back together
Post by: Madruss on March 14, 2023, 10:49:25 AM
One good thing came out of removing the left side fairing was I hadn't bolted the water hose guard in place.
Upon attempting to bolt it in position, I found the clutch line required rerouting behind the hose  :icon_redface:
Title: Re: Now to put it all back together
Post by: Sin_Tiger on March 14, 2023, 10:48:34 PM
Quote from: Madruss on March 14, 2023, 10:49:25 AMI found the clutch line required re routing behind the hose  :icon_redface:

And up in front of and between carbs 1 & 2 following the same route as the coolant bypass hose if you're being pedantic like me  :tin hat 

The plastic over engine shields look a bit odd  :icon_scratch:  unless that's just your temporary placement.

Coming together nicely though  :eusa_clap
Title: Re: Now to put it all back together
Post by: Madruss on March 15, 2023, 11:33:51 AM
Well there's another re route, the coolant bypass hose seemed a bit out of place.  :occasion14  I'll rectify it. :icon_redface:
The two plastic coil covers were in the topbox when I bought the bike. The previous owner said he never knew where they attached/fitted as the owner before him didn't have them inplace. Where I placed them is correct ?
Title: Re: Now to put it all back together
Post by: Madruss on March 15, 2023, 11:36:23 AM
Ah, another bracket which requires another screw near the exhaust :thumbsup
Title: Re: Now to put it all back together
Post by: Sin_Tiger on March 17, 2023, 10:39:52 PM
This might help.

Title: Re: Now to put it all back together
Post by: Madruss on March 19, 2023, 10:24:46 AM
Well  :icon_redface: now this all makes sense.
I'm in Australia, those parts were inside out & upside down  :nono
Correct fit now  :icon_study:
Title: Re: Now to put it all back together
Post by: Madruss on March 19, 2023, 10:28:04 AM
The overflow hose routing was corrected before we refitted the mikuni's too!
Supposed to be Autumn but 35c on my western facing deck  :icon_frown:
Title: Re: Now to put it all back together
Post by: Sin_Tiger on March 20, 2023, 02:15:52 AM
 :thumbsup nearer 3.5 here  :icon_eek:
Title: Re: Now to put it all back together
Post by: Madruss on March 20, 2023, 10:52:38 AM
Brrrr
Title: Re: Now to put it all back together
Post by: Sin_Tiger on May 22, 2023, 09:11:35 PM
How's the rebuild going Dude  :augie
Title: Re: Now to put it all back together
Post by: Madruss on May 25, 2023, 11:54:47 PM
Unfortunately, at a full stop currently. :icon_frown:
Had a muscular issue with my back. Been off work for a couple of weeks & have re discovered acupuncture, which has put me back on the road to recovery.
Reassembly was going well. After stripping all the fairing etc off to fit the crash bars, I was starting fit it all back together. Other household projects became a priority (the Mrs project's) so it was all packed away in the tiny shed.
When I was ready to start again the back issues arose, so there was no way I could move the Calpyso tiger out of the way for access to the black tiger.
So that where it stands at the moment.
Why I went quiet on the forum.  :icon_redface: Thanks for asking.
Title: Re: Now to put it all back together
Post by: Sin_Tiger on May 26, 2023, 12:36:44 AM
Ask the Mrs. to move it for you  :nod  seems to work when the boot's on the other foot  :ImaPoser

:nono  No I'm not brave enough for that either  :cp  :blah 

Hope you recover well, keep it moving but gently  ;)
Title: Re: Now to put it all back together
Post by: Lee337 on May 26, 2023, 11:50:02 AM
Sorry to hear of your 'other projects' and the misfortune of your back issues. I understand how life can sometimes get in the way (see Daysie Daytona's diary).

Hope things improve for you soon & you can get back to what matters  ;)
Title: Re: Now to put it all back together
Post by: Madruss on July 01, 2023, 08:19:15 AM
Thanks for the good wishes  :icon_salut:  :wave 
I'm on the mend after multiple physio & acupuncture visits although any sudden "jarring" on a rough road or hitting hidden stumps or big rocks at work (I operate a road grader for our local council doing the unmaintained tracks/roads) leave me gritting my teeth.
We're in our Aussie winter here (more like your autumn:icon_smile:) so I'm in no panic to put the tiger back on the road till October.
I should be physically "together" by then, raring to go.  :thumbsup
Title: Re: Now to put it all back together
Post by: Madruss on October 24, 2023, 12:52:07 PM
Well October is nearly done.
Getting motivated to pull both Tigers out of the little shed.
I'm back on track physically but still carrying too many kgs  :icon_redface:
Changing jobs in a week or too, so will really want to see the bike come out of hibernation, before I head away till Christmas.
Title: Re: Now to put it all back together
Post by: Beernard on October 25, 2023, 09:00:41 AM
Good on ya, Russ. Injuries are the bane of our existence, but if you are good to go, then go!!
All the best.
Title: Re: Now to put it all back together
Post by: Madruss on October 29, 2023, 10:01:30 AM
I pulled the pin on Friday, a week earlier than I had notified work, using some personal leave etc so as not to prolong the agony.
Two years of working a large government entity with words of respect, teamwork, accountability were making me sick. What an absolute load of :Topes
Time to restart some projects 
Another automotive project I've been trying to complete had a minor setback after lunch, so I decided to clear the way to extract the calypso tiger from its winter confines catch some sunshine, from behind various garden implements  :icon_neutral:
After the sweep out around the black tiger & some repositioning to the centre of my massive structure  :icon_rolleyes: the first task was to attach the shite flap (sent all the way from Scotland) thanks Niall  :occasion14

Title: Re: Now to put it all back together
Post by: Madruss on October 30, 2023, 10:40:34 PM
Back to why I started this job, straightened this brake lever :icon_confused:
Title: Re: Now to put it all back together
Post by: Madruss on November 06, 2023, 10:25:46 AM
Refitted the fairing & fuel tank today
Thought I better bleed the clutch but the top of the master cylinder doesn't want to "come to the party"  :cp & come off.
I remember some months ago I had a similar issue with the brake master cylinder. Differing metal corrosion from what an aircraft engineer mate told me of. Steel & aluminium in close proximity  :BangHead
Found a replacement clutch master cylinder some time ago, on special on "fleabuy" so it'll probably be pressed into service soon.   
Title: Re: Now to put it all back together
Post by: Madruss on November 06, 2023, 10:30:06 AM
Forgot how "battle scarred" this old moggie is.
Being owner number 5, she's probably used a few of her 9 lives to date  ;) 
Title: Re: Now to put it all back together
Post by: Madruss on November 08, 2023, 12:58:13 AM
Well, I didn't need to swap out the clutch master cylinder (MC). I located my trusty impact screwdrivers' small phillips head tip.
I had to tighten up the MC on the bars for the operation. Success  :nod the screws departed their home.
The clutch bled through well, with a big air pocket in the bleed tube & all's well in that department.  :thumbsup
With the battery connected, idiot lights illuminating but the brake light was on! (forgot how bright 2 bulbs in there can be)
Played with some connections & rear switch but still on.
Fuel on, fuel filter full, clutch in, along with a fully charged new battery, choke on.
Wind wind wind wind (or for our American bretheren crank crank crank) :icon_redface: 

Take 2, this morning, removed the right side carby bowl screw, yes fuel & replaced. Then removed the fuel hose off the tank & blew fuel into the system.
Fired up but stopped. :BangHead
Repeated the procedure, success :icon_mrgreen:  of sorts, ran 60 seconds or so!
There must be some blockage  :^_^ 
Title: Re: Now to put it all back together
Post by: Madruss on November 08, 2023, 01:44:37 AM
Success  :friday Removed the 300mm long fuel line off along with fuel filter I was trialing (was going to shorten the hose to fit) & it goes  The brake light staying was just a bad sensor on the rear, easily replaced with one from the Calypso bike  :thumbsup   
Title: Re: Now to put it all back together
Post by: Madruss on November 08, 2023, 04:35:18 AM
:occasion14 first ride in nearly 3 years :wings
Still adjustments to do but it's rideable. On the test ride I remembered how low the seat is. The "Coleman comfort seat" cover will be reattached along with the "airhawk" inflatable cushion to restore some riding height.
The seat from the Calypso tiger is all marked out to change it's "low rider" profile to a DR 650 profile but not as hard as a surfboard.
Title: Re: Now to put it all back together
Post by: Beernard on November 08, 2023, 07:37:22 AM
Great work, Russ! :><

I can report that some years ago I replaced the MC cover screws with stainless allen heads and "reasonably" regularly turn them out and in. So far, so good!

Good to see the cat on the road.

Regards, Bern.

Title: Re: Now to put it all back together
Post by: Madruss on November 08, 2023, 10:52:36 AM
Thanks Bern. I'll keep that in mind.
Gave the little shed a good clean up after the big cat was evicted.! She took up so much real estate for too long, then once Calypso moved in, well! [attach id=19150]
So, this looks like the end of this post, at last.
The little XR100R has had a full engine rebuild, just requires a carby. A 1988 model for my youngest son. He's an '88 model himself.
Thanks to everyone's enthusiasm & assistance on here, especially Sin Tiger (Niall) who without it, I may have thrown in the towel. Cheers 
Title: Re: Now to put it all back together
Post by: ssevy on November 10, 2023, 11:26:50 PM
Those master cylinder screws were "JIS", not Phillips, at least on my '95. On my bike, they had a dot stamped next to them. I use a Vessel "JIS" screwdriver, and it works really well, I have used some grinding compound dabbed on the end to help increase purchase on the screw; a couple of raps with a hammer to seat the driver or bit helps, too. Prior to discovering they were JIS and not Phillips, I had to drill out a few, and I used a left hand drill which spun them out or broke the heads off, which was where they had galled. The remaining threaded portion just came out with my fingers. A rub of never seize just on the shoulder area of the screw is good insurance against future galling. I usually replace my brake fluid at least every other season, and so far the screws have been fine now that I have the never seize on them.
Title: Re: Now to put it all back together
Post by: Madruss on November 11, 2023, 11:54:03 AM
Quote from: ssevy on November 10, 2023, 11:26:50 PMThose master cylinder screws were "JIS", not Phillips, at least on my '95. On my bike, they had a dot stamped next to them.
Well I've learned something new.
Luckily stars must have aligned as to making this a minor job.
Title: Re: Now to put it all back together
Post by: 93TigerBill-2016 on November 11, 2023, 10:14:32 PM
Agreed on the JIS screws, and the 'Vessel' driver.  I have one which includes an Impact function - works a treat!  I also used 'never-seize' on all screws/bolt threads.  It may go some way to alleviating the electrolysis issue as well?

Good the see the Black Tig operational!!
Title: Re: Now to put it all back together
Post by: Madruss on November 11, 2023, 10:50:08 PM
it was so nice to take the Tiger for a shakedown ride on Friday.
I overtightened the chain by mistake too. It looked fine but after inspecting it upon returning, fairly tight.
The screen appears a bit off centre too. I repaired the framework some time ago but upon the refit, the left side was a bit tight.
The instrument cluster & fairing don't coincide either. The fairing frame on the Calypso looks straight, so it'll be swapped sometime after the Christmas break. (grandkids visiting)
The preowned Hepco Becker crashbars from the Calypso, fit with the rest of the ol girls battle scars !
A little bit of fine tuning after the novelty of listening to the 3 cylinder growl wears off. :rock-1:
Title: Re: Now to put it all back together
Post by: ghulst on November 28, 2023, 08:38:54 AM
Well done Russ! She looks good out in the country. I personally like an adventure bike with battle scars. It makes you less scared to just send it and see. Which often ends up much better than carefully trying to navigate a rougher bit. 
Enjoy!
Title: Re: Now to put it all back together
Post by: London_Phil on November 28, 2023, 04:35:08 PM
Still one of the best looking bikes out there.
If only they were EFI...
Title: Re: Now to put it all back together
Post by: ghulst on November 30, 2023, 09:40:25 PM
Well, that is something that can be changed. Not cheap, but it can be changed... ;-)
Title: Re: Now to put it all back together
Post by: ssevy on December 08, 2023, 12:33:31 AM
While rebuilding the Mikunis is no picnic, once I did mine and then ran non-ethanol fuel, I've been trouble free. Fuel injection is probably great, but I am still impressed by what a carb can do when it is set up correctly. I did stop at a Triumph dealer to pick up a part, and I wouldn't feel bad about owning any of the new Tigers. I sat on all of them, and was quite surprised that I had no issues touching both feet to the ground. Probably never will afford one, but for me, I'd gladly trade fuel injection for shaft drive, as the chain and sprocket maintenance is more of a pain for me than the carbs.
Title: Re: Now to put it all back together
Post by: ghulst on December 08, 2023, 11:02:48 PM
Carbs can be great, if they are working nicely. However, when they go wrong... And that is one factor that EFI has a bit less. I enjoyed my Tiger 800 with injection. I have looked at the 900, but in my opinion it was so close to the 800 that I didn't really see the point for the extra expenses.

Having said that, I would prefer EFI and shaft drive...

Which means I will probably end up with something old and ratty again. ;)
Title: Re: Now to put it all back together
Post by: Madruss on December 23, 2023, 07:16:24 AM
Quote from: ghulst on November 28, 2023, 08:38:54 AMWell done Russ! She looks good out in the country. I personally like an adventure bike with battle scars. It makes you less scared to just send it and see. Which often ends up much better than carefully trying to navigate a rougher bit.
Enjoy!
Thanks mate.
have a nice Christmas.
Big damaging storms predicted over South East Queensland for the next 3 days. Glad we're staying this year
Title: Re: Now to put it all back together
Post by: Madruss on December 28, 2023, 10:15:28 AM
Some wild storms have hammered south east Qld over Christmas.
Good beer drinking weather here on the range, 34c today.
Title: Re: Now to put it all back together
Post by: Lee337 on December 28, 2023, 03:04:38 PM
Wet, windy & 10c on the other side. Bikes firmly tucked up in the garage but all being well with the weather, I might take the Tiger 800 out new years day. (Working through Xmas - New Year so no beers for me just yet.)
EhPortal 1.34 © 2024, WebDev