Today, I finally, managed to remove the pesky clutch actuating arm needle bearings - tried heating in the oven, tried freezing but those outer races were stuck in solid. Even managed to break the blind bearing puller tool. Tried the rawlbolt trick, which was successful for removing one race (yey!), but just wouldn't get a grip on the other one. Eventually, I used a small grinding tool in the dremel to carefully grind away the stubborn, hardened steel until it was paper thin and as I broke through, it simply popped out!
The rebuild went reasonably well - I opted to use the oilite bushes (as suggested by SCP) rather than new needle bearings - and packed the actuating arm with copious amounts of grease. The bushes were a tight fit, but I reckon that it will be easier to remove these bushes than the needle bearing (when the time comes).
New boot and jubilee clip fitted (longer bolt definitely made the job a whole lot easier) and adjusting bolt screwed in and locked in position. Finished off with a nice fresh helping of AP5 gear oil into the gearbox.
Exhaust went back on without any dramas (another dose of copper slip grease on the studs). Moment of truth time (again) and with Gretel on her centre stand, I fired her up and checked that I was able to shift easily through the gears - so smooth!!
After a short time running, into order to warm up the engine oil, I shut her down and completed my final job - an engine oil and filter change.
On a relatively warm, almost Spring-like day with dry roads and the sun shining, I rolled Gretel out of the garage - it was the perfect time for test ride. Gretel purred in anticipation as I pulled out onto the main road - I noticed the the clutch biting point was a little higher than it had been and the ABS system wasn't clearing as it should, but gave her a short blast see if there were any other obvious issues - there weren't. I returned home for a quick pit stop to adjust the clutch and check the ABS fault code with the test box - 4 flashes indicated a rear sensor error and, after a quick dose of DeOxit into the rear sensor connector, I was able to successfully clear the fault.
I was then off for a second test ride and Gretel was running like a dream, rolling around the corners on her new rubber and a featherlight clutch. A quick 10 minute ride became an enjoyable hour as I swept effortlessly along the highways and byways of Somerset. Gretel was back and looking good in her new Diamond Grey colour scheme.
All shiny and new looking - job done!
...and next weekend, Heidi will get some much needed TLC too - she's already had a new screen and there's a box full of bits sitting in the garage waiting for her - clutch actuating arm bearings (I'm a glutton for punishment!), brake pads, oil change and de-stickering...what's the point of reflective stickers if the buggers don't look?
Thank you to all forum members for the encouragement, top tips and advice during the rebuild.
Thirteen weeks to the day and Gretel
has come back to life.