what did you do with your fazer today ?

[fazerscotty]

Not today, but Friday 24th, went to Selby and back for work (from Worcester). Nice run out, cobwebs well and truly blown out.  :lol :lol :lol

[coffee]

I'll bet ! that's a fair old run.   any reason Selby ? surely not a regular commute.?

[Grahamm]

Had a quick look for JIS screwdrivers. The cheapest set of 4 made by Sealey (AK4314 JIS) that I could find, and are very similar to my Laser set(Laser Tools 7036), are £13.93, ebay item code 184084743936.

I was looking at these JIS Bits from Bikers Toolbox which go into an impact driver, which is another tool on the list to get...

[fazerscotty]

I'll bet ! that's a fair old run.   any reason Selby ? surely not a regular commute.?

300 miles round trip. I go up two/three days a week. Normally stay in a hotel, which is shut  :'( , so its a 300 mile day twice a week for now. I visit a small airfield near Selby, where I inspect and certify work carried out.

[Grahamm]

Ye saga continues...!

I decided to have another go at the screw fittings on the brake hoses that go to the ABS modulator after squirting them with Plusgas for the last few days, but still no luck


I may have to resort to a blow torch at some point, although I'm going to have to do that carefully because a) there's bits of bike right behind them and b) from what I recall, brake fluid is flammable!


In the mean time, I figured I'd have another go at the rear shock. I'd been up to B&Q (now open, but with 2 metre lines all over the place) to get an M8 bolt and some appropriately sized washers to create a "bearing puller" that should (supposedly) mean I can remove the sleeve at the bottom of the shock and get it out, because, at present, the shock is stuck against the underseat storage compartment.

I did think about trying to remove the underseat storage, but that's attached to all sorts of other stuff such as the seat lock and, it seems, even the wiring at the left rear of the bike, so that was a non-starter.

Anyway, I got a piece of aluminium tube that would go over the metal sleeve at the bottom of the shock and started trying to pull it out.

And tried...

And tried...

And not a bloody millimetre of movement could I get (I'd been squirting that with Plusgas too...)

Ho, bloody hum.

Might be another blowtorch job...

Alright, I've got to remove the exhaust because I want to check the swingarm bearings and also (as mentioned in a previous post) it's blocking the way to get a stupid metal plate out of the middle of the bike (another piece of ridiculous design by Yamaha  :2guns ) so I can get access to the ABS modulator.


So off with the header bolts (dead easy, fortunately, because I'd taken them off and Copperslipped them when I had the new engine installed a couple of years back :thumbup ) and then removed the bolts holding the bottom section and the cat pipe and silencer section.

I decided to try to do this without removing the silencer too and, fortunately, after a lot of wiggling sections around and so on, I got the cat pipe out.

Just as I was doing this and feeling relieved, there was a "Clonk" as the rear shock suddenly pivoted on its lower mount and dropped to the ground and I'm staring at it thinking "How the FOC did that happen...?!  :eek )

Eventually, after looking a bit more, I realised that the cat pipe was blocking the swingarm from dropping all the way down, so, with that out of the way, the shock (which is still attached to the swingarm) could drop an extra inch which meant that the underseat storage was no longer blocking its path!

So that also meant that I'd FINALLY cleared the way to get this bloody ridiculous metal plate out of the way to let me access the connectors on top of the ABS Modulator!

I'm not actually sure what this plate is actually supposed to do, but I'm seriously thinking of cutting it in half and then sticking it together with a couple of flat metal pieces and some heat resistant aluminium tape so that it'll still sit in place, but, if I ever need to get it out again, I can just cut the tape off, remove the plates and take it out in two sections, making life a hell of a lot easier.

At this point, I decided to chalk that up as another win for today and leave anything else for another day.

Here's a pic of the offending article (the thing at the top left is the ABS controller)

[agricola]

Just a thought Grahamm, the metal sleeve at the bottom of the shock doesnt have a thread in it, so I dont follow how you could draw it out, unless you tap a thread in it. I cna corfirm its a bastard to get out though. Try to get some rotational movement first, dremmel a slot in the end so that you can get something on it and tap it around.

[Grahamm]

This is what I'm using:
80mm M8 bolt

Aluminium Sleeve to go over the one on the rear shock and a couple of 25mm penny washers to spread the load.

On the other end are two M8 bolts (locked against each other) and two 12mm washers which press against the sleeve.
The idea being that, when I tighten up the bolt (with a spanner holding the nuts at the other end, obviously!) it should draw the sleeve out of the bottom of the shock mount.
Except nothing would move

Tomorrow I'm going to try the blow torch to heat the two sides of the shock mount and hopefully that will expand them enough that I'll be able to get it moving.
I've heard of people using mole grips etc on the sleeve or, as you say, using a Dremel to cut a slot or even welding a bolt to the end so they can use a breaker bar on it, but I'll leave those for later...!

[agricola]

I could have sworn that when I had mine out, the sleeve fitted up against a shoulder, with about 10 to 12mm sticking proud on the right side. If im right, thats why you cant draw it out, youre drawing against the shoulder

[Grahamm]

I could have sworn that when I had mine out, the sleeve fitted up against a shoulder, with about 10 to 12mm sticking proud on the right side. If im right, thats why you cant draw it out, youre drawing against the shoulder

Damn, having had a look with a fibreoptic scope (bought it a couple of years ago for the hell of it, glad I did now!) it seems you're right.


What I *thought* was the end of the sleeve on the left hand side, is probably just the marks left from the end of the bolt that goes through the bottom of the rear shock


It didn't help that the bloody Haynes Manual shows the tool I made up in the Tools and Workshop Tips section and says "Hey, you can use this to get the bearing out of a swingarm".


Of course if Yamaha had made it a sensible design in the first foccing place...


Agricola: When you say "Dremel a slot", do you mean like a screwdriver slot that goes across both sides of the sleeve?


Also did you use heat? ISTR warnings that a butane torch can melt aluminium, so I don't want to wreck the swingarm if I try to heat the sections each side of the bottom of the shock...


Any helpful tips would be welcomed.

[agricola]

Yes, I dremmeled  a slot across the end face of the sleeve, big enough for a blade to fit in. I also dremmeled a slot/groove onto the outside diameter near to the end face of the sleeve, so that I could get a smallish chisel/punch etc into the slot, then tapped it out from the left side of the bike. Prior to punching/turning with the blade, I red heated a piece of round bar that fitted into the bore, and slipped it into the bore and let it transfer the heat into the sleeve. Add in release oil, and patience, and I finally got it out without damage. I wasnt concerned about the needle bearing and seals cos I was replacing them anyway

[Grahamm]

Ok, thanks for that :thumbup

I'm going to have to think about this and have another try tomorrow.

[agricola]

You could also try a split collar clamped tight onto the od thats proud of the frame. Couple of tapped holes in the collar and it could be used as a jacking tool to jack the thing out, or help it out with a drift from the left side.

[Fazian]

Fitted anew screen, tail tidy and LED indicators!

[Grahamm]

You could also try a split collar

I had no idea what one of those was, so I searched it and the images look *just* like one of the products I sell...!!!  :rollin


Well, anyway, I haven't, yet, managed to shift the sleeve on the bottom of the rear shock. I tried heating the bracket that holds it, then zapping the inside of the sleeve with some freeze spray, but it didn't want to move.

However I have finally managed to get all the brake pipes off, although that was a palaver.

There are another couple of screw connectors just above the gear box, but I was unable to get them to move and one started to round off.

So I decided to try heat on the ones at the front and, after putting some aluminium foil behind them and then a wet cloth, I heated them up and, joy of joys, they shifted!

I did also try this on the ones in the frame, but didn't have any luck with them, so, instead, I decided that if I could wiggle stuff around enough, I might be able to pull the hard lines and the hoses to the ABS modulator out via the front of the bike.

Sounds simple, but it took me over half an hour trying to get everything through tiny gaps...


Anyway, eventually I got it all out, so I might have another go at freeing the screw connectors tomorrow or, if I feel up to it, having another shot at the rear shock.

[unfazed]

You could always convert it to conventional brakes  :rolleyes

[agricola]

You could always convert it to conventional brakes  :rolleyes

Wouldn't that mean the ABS light would always be on? If so, thats an MOT failure

[coffee]

Fitted anew screen, tail tidy and LED indicators!

:useless

[Grahamm]

You could always convert it to conventional brakes  :rolleyes

I've only had the ABS activate on the front wheel *twice* ever since I bought the bike 13 years ago.


One time I remember well was when I was on a Ride Out and following a car down a country road.


We were just going around a bend and I was getting ready to accelerate and pass them after we'd exited the corner, when they suddenly must have realised they'd missed an entrance they were going to turn in to, so they slammed on their brakes.


I was far enough behind (of course) that I didn't have to emergency stop, but I did have to brake firmly.


Unfortunately there was a patch of gravel that I couldn't avoid, so, as I braked, I felt the ABS cut in, I then stopped safely.


Had I not had the ABS, I'd probably have ended up on the ground.


So, thanks for the suggestion, but I'll keep it :thumbup

[Fazian]

[quote author=Fazian link=topic=6412.msg313783#msg313783 date=1588422637]
Fitted anew screen, tail tidy and LED indicators!

Oh go on then  :rolleyes  just fitted the belly pan too 
Before and after pics.











:useless
[/quote]

[coffee]

Very nice, :thumbup