great day out with some of the guys round here

the fuel cooler mod is fantastic ...a very noticeable temperature difference between the rs of blakey  and old gerty

stirred up some rubber around the twistys on the way home

those chicken strips took a beating from this old fella ...

and a big smile on my face after the trip with friends towards a verry warm Kingaroy in the hills  not far from here

You'll be needing some new Knee sliders then?  

Cheers,
Paul.

got bored ...

thought of putting a badge where the horizontal lines are on the air filter box

Ok Charlie,

if your are getting that bored, I have a project for you down here in Sydney. I've got all the cleaning stuff you need and most of the tools!

   :joker:    :joker:     :joker:  :joker:    :joker:    :joker:    :joker:    :joker:    :joker:  

Jez

bit more clean up







whatcha think ?

Wow, I hardly recognize the old girl mate!?    I just luv those color matched city bags...I've really got to see if I can find a pair!

Best,
OG

gday og ...good to see you ol mate

yeah get a chance at cleanup ....sometimes when im not out on a day trip or two

cheers !

Looking good Charlie.  

Gets me thinking about painting more of the plastic bits.

Paul.

Spotted the suspension support for the first time.  

suspension support works well paul ....many thanks

had a chance to change the rubbers on the crank cover retaining bolts and the seal ...a teriffic difference in pull up tensions from the old compressed rubber that were in there .
i had to cut a few of them as they had become so hard over the years that i could no longer expand the rubber over the retension shoulder on the bolt.

Real nice job on the crank cover. How'd ya do that? Painted by hand?

That I may like to copy if you haven't got a patent on it.  

lots have done similar aj .... i see in some of the pics around the place

not hard to do ....but do remember to wait till the black goes off properly (give it a day or 2 ) before hitting it with the clear coat .....you can just see some bubling in that pic (sad to say ) around the bmw lettering

hand sanded back from full cover over the whole strip ..to give you an idea .

finish on the aluminium is with scotchbrite ......( the divots and corrosion from the old fairing rubbers on there ) were really hard to get out ....but the scotchbrite  gives a matt finish and hides some little imperfections quite well

glad you like it .....polished was on the menu ...but alas i wanted it finished and back on the road the next day  

enjoy !!

You are getting too "showy" now Chas, may have to change the thread title?

I admire the way you have done all this work while keeping Gerty on the road as much as possible,

I dips me lid to Ya!

had an inspection of the rear brake pads before the karua event

bit sad on one side ...but that seems  ...erm normal



maybe these old ones I have from the fronts will get me through a few months



also installed a bit of a mud flap to protect the clutch arm bellows etc ...before heading into the bush next weekend

I wonder how many GPI failures would have been saved by your mudflap Charlie?

indeed mike

just found a weeping bellows on the clutch push rod spring assembly  . which I had changed just , what seems a few months ago now 

the only thing I can think of is a bush bash heading back from the "highlands ride "  some months back ..lots of rocks on that 30 odd ks  through the "white swamp" detour we made ...bugga...  I guess I better get a newie  ...fairly peeed off about that ...and drained white-creamy transmission oil from the gearbox

does anybody have a pic of the location of the gearbox breather ??????????
thinking its about level with the battery tray some wheres   ...um under the starter ????

Charlie, as you say, it's under the starter, the black "button" thing just like the one on the final drive.

thanks mike
mind playing tricks on me again ...I guess its not something one looks for very often ...grin

did I mention that I have installed the modified throttle bodies ...when I did the repaint of all the airbox stuff .

after lubricating all the working bits around the cable . throttle grip assembly (hasn't been done for well over 18 months ) I have a nice smooth and light action

I hadn't checked to see if the throttle body linkages were all lined up properly before installing ...but found it hard to achieve a nice low idle .

a bit of adjusting and road testing  and I think I got it close without the vacuum gauges ..(but will apply them when I get a chance ) the link from the middle to tb number 2 was way out by more than a mill or 2 ....eeek ...a cut down paddle pop stick in a wedge shape was a good gauge to get in there and get them close ...adjustment screws all to about 1 turn out on the bypass

acceleration is pretty good ....although remember I am running on empty pretty much lately ,,,so everytime I take off with a big handful ....yes the fuel runs away from the pump ....splutter splutter ...

one thing that I have a sneaky suspicion about though is ...that there must be a shorter chain adaptor at the handle grip gear interface ...I have found that with the new cable and bracket installed back then, I have a good healthy 20mm or so adjustment taken up on the top adjuster to compensate .

I recon there is probably a shorter version somewhere
any insights ?

hard to tell from the bins site ...I recon it might be the removal of a link or 2 on the chain to cable gland ?

think I found it


just what someone wants to do on a hot sunday afternoon ...exhaust off and all the rest to replace a pretty hard bellows from supply ...I knew this might happen ...the replacement is much more ...erm flexible ...hope that mud flap helps

my thermostat mod

for years i have been trying to solve heat issues on old "gerty"

things took a turn for the worse just the other day whilst riding home from work ...the old girl decided to spit some fluid out and turn on the fan by herself and heading way up to 100 c on the guages (hardly ever seen that before )

well all things came to a point of realization that i better do something about it ..now

we had tested the thermostat some while ago ( alby the amazing ) ....after fitting the 3 core radiator ...some good results followed ,,,but never really solidly stable ...with an every now and then high running temperature ...i know shes not leaking fluid from anywhere important ....been looking for things for ages ...and never need to top up the fluids as a general rule of thumb ...but every now and the the poor old darling shows me she is getting hot under the collar .

folks were looking for the right gasket (donut seal ) for the thermostat to fit in the radiator in another thread on the forum ...and i had done some previous investigation towards this ...

"neds" post from long ago confirmed that the toyota thermostat fitted up nicely ,but the seal was not a good fit .



but new to the mix was a newly designed and released "hi flow option" thermostat ...and you guessed it, a release appropriatly with a version for the old "rolla " (toyota corolla - rolla )



hmm ...his looks interesting .



the apature was about 5mm wider across the diameter of the working valve than the bmw ...and maybe 6 or so wider than the original..."works good" and nearly forever ... toyota standard replacement .

so i grabed the "indicated " as compatible seal as well ...even though i knew it wasnt going to fit square ...from neds post

and a couple of the other ones i had investigated a long while back (making a possibility of at least three options that may or may not fit in that widdle hole )

the recommended ,. about $ 2.50 at 50mm od x 6.5mm ...

the next size up , but with known square section , about $3.45 a tad over 50 mm od x 4.?mm ...(i could always cut some length out of it and sit it in there with some down preasure from the retaining cap with a dab of high temp silicon just for giggles) .

the other option was a tiny bit smaller $11.50 (ripoff bastards )...but would stretch to fit at 48mm od x 4.? mm

the recommended was too wide in the hole ...the cut out of the profile left about 2.0 2.5mm of outer wall to the od ...i had thought this is never going to fit round te circumfrence and stay at 50mm

which prooved correct ...the slight stretch made the thing at least 1mm bigger than the hole it was suposed to fit ...besides the profile was all wrong for the radiator , in this application with a roundish look and the width was about 6.3mm after application to the thermostat .

the rolla has a standard bell type housing and could use the extra gap as takeup, i guess the housing internals was about 55 mm overall id ...

the 48mm one was a perfect fit with a width of about 4.3 mm ...but with the slight stretch wants to lie either inside or outside the radius (high or low of the edge )

lets see if this fits !!!





i worked the seal down towards the venting of the radiator core first , so that the edge would sit correctly then slowly droped the rest in the hole to a perfect sized fit...just touching the edges all the way around

after applying the retension assembly i checked for compression , would it be too much

no not at all , i could screw the screws alamost down to about 1.5 mm left , by hand lightly before meeting some resistance ,,,sweet ! this will let the front seal of the retainer do its job properly against the body of the housing .

one of the things i did notice however was the rear bypass blocking plate was slightly smaller than the original bmw thing , and that the depth between the front flange and the bypass vent restrictor was a few mm deeper into the void on the high flow thermostat.

 

i measured the distances carefully and did a little figuring out ...the new one would only leave about 3-4mm of bypass fluid flow .....not bad, but too close for me ...i wanted something like 6- 10 mm of opening, after seeing the reaction of the thermostas at temperature

this may have been important ,, so i experimented with the actuation of the thrmostat whist at temperature

i could see that the new device threw further into the housing and closing off the bypass quicker ...maybe not so good , and that the spring tensioned bypass restrictor could offer a little too much back pressure , before opening fully . (as i suspect the bmw one was failing to do on a regular basis and letting uncooled fluid circuluate through the system )

i noticed how much change there was between closed and open distances on both the bmw one and the new device ,

hmm ..flared copper ,,, i wonder ,,,yep cut it off at the flare to allow me to a modify it a little ,

so cut off about flush with the flare of the rear retainer , i cut a few slots about 5 mm into the length of the flange , the aim was to peen these over and retian the blocking plate again , also i cut about 5mm out of the spring to match the relative tensions that i thought would work out right without presenting too much pressure against the opening mechanism

the rear plate although smaller would still do the job admirably after measuring the bypass port





dully filled primed and no leaks with new fluid , test ride ....

sweet ....it didnt skyrocket at all, just sat comfortably about 86-89c with a little ride round the block ...

i stopped for a while after warming to let her tickover ..... a sure temperature rise exersize ...no rise at all ...yippee


results of a 600k plus ride around the loop ...amazing

after a 150 k freeway ride up near 4.5 k revs ..with some spirited back roads towards the end (higher revs ...grin) and arrival at bryon bay ... a real traffic jam was encountered as usuall about 3 kilometers out of the small town on market day .


..20 plus minutes idling away, then mooving forward a car length ...normally sure to tweek me to hit the manual over ride of the fan to extinguish flames from under the tank sorta stuff .........no ...not a budge cool and quiet was the old girl ...maybe nudging 91 c ....no problem at all ..

another 250 k across mountans ,,,hills and dale had me up in stanthorpe to visit rick


still no issues ...that temperature guage was stuck there ...never budging from a few degrees of moovement ....in fact riding at about 80 k/per hour has it the warmest ...as speed increases the temperature drops slightly ...what the ....?!!!

still some 200 odd kilometres from home the night ride ran well ...down the big hill

i can see now why the 2 core radiator was used on all susequent versions of the k after 85 ...three cores just isnt needed at all ...and in cooler climates ....does the thermostat ever come up to full working temperature ? left me wondering !!!!

if your up for a little grubby hands on playing ...do this mod ... it isnt particually hard to do ...it wont cost the earth ...and i recon will come out cheeper than buying "original" from here or overseas .......and works really well .

total cost (at retail) including bits i was never going to use ...$54.00

i really wonder should we start a ..."this works for me, mod" type topic .... that many could contribute to ????

there are so many good and reliable "known solves" already in this forum from many advanced and knowledgeable contributors .



what do you think ?

bit more cleanup after "the leg too short" downhill lean over  event on the "big loop ride " ...yet again

I had broken the footpeg ...after a steep up hill stop at an intersection ....no issue , till the driver in front took off ....reversing a few feet ..almost into me before taking up and moving forward.... yeah yeah panic ...so I backed off a little ,,,,but weight transfer took me downhill for balance  ..my legs aren't that long ...sheesh !

gerty laying on her side still running of corse ....but bits had broken ...including mirror ....and foot peg ,crikey they are sprung loaded that shouldn't happen ...but the down hill angle on me going backwards and an acute angle ....snapped it clean off about 30 mm out from the pivot

 

fortunately I carry a fair few tools and decided there was nothing to do but swap the rear footpeg to the front ....so that I would have at least some purchase on that side after the reattached part went missing about 10 yards up the road ( the foot rubbers don't hold it that tight ) never t be found again .

I made the run to Lismore to visit more family ...then Stanthorpe to visit rick as planned ...but late ...and then home down the hill

so seanii had sent me a replacement 83-84 peg ...after enquiries to the "bm shop" became unanswered
(cheers mate !! appreciate it )

dully fitted and modified so that the rubber wouldn't work its way off the peg whilst riding ...(there is a end weight on these old ones ...but I didn't have one ...which also holds the rubber on the peg )

I was amazed at the clean look of the parts after a little light restoration , stainless retention spring ...pivot pins and all cleaned up now

changing the colour of the paint on the passenger peg support bracket also made a new look to the whole section

 

in comparison to the other side



whilst there ...with paint out and wet and dry in hand , I pulled the passenger grab handles ...damaged from a few years of rally event luggage hookup



along with a bit of paint repair to the city cases ..where they held gerty off of me ...whilst laying down



of corse the mirror pods spit apart ...again ...bugga !



but I had a reserve ...thanks to blakey ..our good friend ...off his "barge arse" project (forever in gratitude  ol mate )



"will" 88ke  from the "irish etcentrics" offered the thought of doing both sides to make a good deal out of a bad one  ^5s

so I continued


hmm looks good

the grab handles went back on ....with a little colour change to the pockets behind



and the mirror pod looks great

Looking good

thanks waz

is the old girl becoming too light ......I mean all that deleting .. progressively ,all of the black
highlights ?

It proves that an old bloke with an old bike can be both repaired and going like new.

The bikes are easier to keep going than the blokes Stan. Every time they try to fix me I feel 10 years older.

Rick, if that is the case you look pretty good for a bloke who feels that he is 120 years old. The blokes keep the bikes going and the bikes, and repairs, keep us going. Dementia is being fought by us and our travels remind me of the saying......travel before you unravel. Our forum has created a community.

community indeed stan

thanks for the thoughts ...

are you coming to ninja gully ???  would be good to see you again ...our sessions always appear too short when we get there ...
maybe its just me preoccupied with many things


cheers

ainsjac wrote:It proves that an old bloke with an old bike can be both repaired and going like new.

Bang on Ainsjac!.....both of them  

Just keep the fluids right in both of ye Charle and there's a couple of hundred thou in both yet!  


Nice job Charlie. As a matter of interest did you find it hard to get the pins out of the old pegs? - I believe they can be a bugga!

hey will, your probably right for all those folks that live in wetter climates ....for me the spring tension wasn't too bad as extra leverage on the pin assembly . but the tolerances through the peg itself are tight.
it seems to me that a lot of crud-corrosion  would make it real difficult .
in any case I clear coated the pins after cleaning them up and took just a small amount of crud build up out of the peg hole with an arbour (made of some rolled up wet and dry ) ...to allow a snug fit rather than a tight one .
hopefully this will keep it with a free movement in the future ???

Charlie, that date unfortunately lines up with our youngest having a 21 style birthday. Looking forward to seeing you blokes soon.

now I have a key to lock the city panniers at last  

lets give this a try







some nicks and scratches ....but hey !...loads of character

some anti vibration rubbers  ( which stop the self suicide tendency's ) in the right places




even with the upside down footpeg rubber ....giggles

looks neater from the rear end

With all your work Chas you gunna have to change your thread title, it's a SHOW bike now.

That wheely bin looks wheely good in that colour, new thread, bin renovation?

Good work mate, Gerty looked great at Tottenham only a few months ago and you have done 

heaps of work since, Respect.

Hi charlie 
nice work on the panniers
i have a set of those that neads a little care and attention;-)
I just might steel the idea with the rub ers
But how thick are they?

K-rider

Ghost who rides wrote:With all your work Chas you gunna have to change your thread title, it's a SHOW bike now.

That wheely bin looks wheely good in that colour, new thread, bin renovation?

Good work mate, Gerty looked great at Tottenham only a few months ago and you have done 

heaps of work since, Respect.

+1  

k-rider

hi k-rider
they are about 1/8 thick of fairly medium density foam type rubber

their advantage is that  they hold the pannier to the frame well ...in the process stoping any up down movement as well ...( for many degrees of angular movement away from the verticle ) at the bottom (like when the frame lock opens .....erk )

the bit near the frame lock supports tension on the lock all the time so limiting the vibration of the lock mechanism ...btw I have some "jandal - thong" type rubber in the frame lock tongue  to close the gaps up .....from many years of neglect and some now increased open frame to tongue distance ...if you get what I mean

if you would like I can post a good close up of the material if it helps ...its more a combination of polypropolene and rubber than full on rubber 

the process of non slip and anti-vibration is by adding friction from a compliant foam structure  
hope that helps ....

cheers ghosty ...doing what I can mate

you like the wheely bin ???  so does the owner (not me ) ....grin ...

Charlie....do not inform people of Aussie secret uses of thongs.....remember it is a national secret.

Hi charlie 
yes please post a picture, when you have the time.
i quess it is a bit like the neoprene used for wet suits?

K-rider

yes neoprene is very similar

some irish on gerty .....not permanently placed yet

Good work Charlie.

The back end looks tidier.

Are they getting rid of rego labels in qld?

ainsjac wrote:Are they getting rid of rego labels in qld?

As from October next year.

I guess so stan
might have to come up with some rear mudflap bling ...perhaps ? ....  grin !

Looking good Charlie.  

But I can still see some black bits!  

Paul.

slowly slowly paul

so did some stuff this weekend as well


painted pods and mirrors (thanks blaKey ) made it on now







handlebar bling

I like it Chaz!  Those city bags look great in the silver and nice work on the bars!     Did the bar ends quell the vibes any?

OG

I think so og mate ....they are dependant on nice flexible rubber o-rings s along their length to help eliminate- isolate  as much as can happen ....mostly I have found them hard as a rock ...so probably wouldn't be as effective,  (the concept is quite good ) ..but easy to find new ones ....on the rt bars with a little more length I suspect the anti-leverage works well

there are orings at the clamp part of the retainer some 4 inches inside the bar  and another about 2 inches in from the end weight . just so you get the picture ...I think twb has some after market ones on his rs ...which for him was effective ??!!

Rear mud flap bling...

This'll work!

omg ...thanks for the giggle blakey

thinking something stainless and etched

(we can do that at work )

hey Charlie you mentioned stainless, I have an exhaust on the way, what would you recommend to polish it or any tricks so make it gleem,