Project Z750 part 25

Once the fork legs were at the bike shop, I decided that I could clean the front wheel and front end. At least it would be a clean incomplete bike.

I also put four new LED indicators on. The rear indicators had been broken off by our dogs running round while the bike was sitting, and the indicators that I had were LED whilst the original's were filament bulbs, so I put new indicators on the back and changed the front indicators for the new LED ones.

Once all four indicators were on. I put the key in the ignition and tried the left hand side. Ohhhh, not sure if that's right, but all four indicators are now flashing. I tried the right side indicators with the same effect. I looked for a hazard warning lights switch. Nope this bike doesn't have hazards.

which means something has gone wrong with the wiring. I guessed that the alarm wiring (which used to flash the indicators) needs looking at.

By now there are only two pairs of wires left that I'm not sure of the purpose. so I try each pair at a time with them connected and separate.

Yes, I found a combination that fixed the indicators, so I now have left and right side indicators working as they should. Well nearly. they are flashing too fast, so I need to order a new flasher relay, but that's easy.

Once the indicators were sorted, I finished grinding off the captive bolts from the fairing mounting bracket that I'd had used the dremel on, so that I could use normal bolts in place of the now non threaded rods.

Once I had sanded the mounting plate I gave it a coat of hammerite to help protect it from the elements, and put it back on the bike.

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Project Z750 part 16

The piston puller has arrived. it looks like a pair of pliers, but works opposite so that when you press the handles the "nose" of the pliers expands. the idea is that you put the nose into the piston, grip very hard and turn and pull the piston so that it comes out. the theory is great, but actually using one isn't. in use you are trying to grip as hard as you can, and at the same time trying to pull the piston out of the caliper (as well as maybe turning it if it's stuck like mine). it took a herculean effort to get one of the pistons out, I was gripping as if my life depended on it, trying to twist the piston and pull it out of the caliper. when it turned (a little) it gave me renewed hope of getting both pistons out, and eventually the piston was out, so just one more left. so now on to the fifth and final brake caliper piston. I put the piston puller tool into the caliper, gripped with all my might (no laughing please) and twisted. Well something mo...

Project Z750 part 18

I have done a bit of reading on how to clean brake caliper pistons, and found an article that said you could use fine wet and dry to clean corrosion off them [ http://www.motorcyclenews.com/new-rider/choosing-kit/2006/november/jan26-05-how-to-service-brake-calipers/ ]. as it suggested using 1500 grit wet and dry, I decided to be cautious and start with 3000 grit. I cut the wet and dry into strips about an inch in width. I put some wd40 onto a strip and started polishing the rear piston. After quite a while I started to notice the difference. it was getting cleaner. well, it was working, but it was going to take a long time. well, I was patient and I really didn't want to rush it and ruin the pistons. Over the next couple of weeks, I polished all of the pistons using the 3000 grit wet and dry. As it seemed it was going to take the rest of my life using 3000 grit wet and dry, I decided to take a risk and bought some 2000 grit. yep I was really pushing my luck here. I cut the 20...

Project Z750 part 14

I thought that some photos would be in order rather just all that plain old boring text, so here is a front caliper and it's pistons: This is the caliper before I managed to get the slide off. the pistons show a before polishing started and part way through. Here are the pins that hold the pads into the calipers. again you can see the before and part polished (I hope you can tell which is which) I thought I would show a picture of the rear caliper in pieces: there are more bits for a single caliper than I realised. The rear is a single piston caliper. and one of the front calipers. the front calipers are twin pistons (as I hope you noticed) I dont think that I will be able to remove all of the corrosion from the caliper pistons, so it looks like I will be getting all new caliper pistons. I'll order them once everything has been cleaned thoroughly.

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