Page 1 of 1

Just some musings

Posted: Tue Mar 14, 2017 12:17 am
by Suzsmokeyallan
Taking some time to do some general work on one of my RG500s. One plan is to upgrade the wire harness, one main area was to replace the ignition coil wires with larger ones and add some extra circuits as well and retape the whole thing along with a general tidying up of its appearance.
Recently I began this process and did it with the harness still on the bike, yup it never left the bike while I was working on it. It may sound strange to do this but on these bikes its actually possible and easier.
I also wanted to make custom cables for the power valves which I made and fitted, along with fitting new custom brake lines and caliper rebuilds etc.
I also rebuilt the battery box/oil tank section amongst other things, heres a few photos showing a bit of the work being done.

Image
New custom power valve cables fitted to the motor and one pair of the new ignition coil harness wires can be seen in this photo, along with a section of the retaped harness.

Image
The new location for the main fuse, putting it here makes for a loss of about five feet of the stock wires.

Image
Rebuilt rear caliper with restored hangar bracket and new custom braided ss lines/fittings.

Image
A customized shift unit using some of the orignal parts along with a modified GSX600 lever for a shorter throw.

Image
SS flange bolt on pipe bracket, very decent quality items. The footest bracket was also customized and then restored.

Image
New alternator yellow phase wires, upsized to 14 gauge.

Image
Rebuilt battery box plate/oil tank looks way better now its been upgraded/restored. The two pin connector shown is an addition which will be used for the JDM fuel gauge temp gauge unit.

Image
The four carbs were removed and ultrasonically cleaned then rebuilt. The throttle cable assembly and choke cable assembly was also rebuilt.

Image
The radiator has been restored and will go back in shortly. All of the Tygon lines are new as well as the oil lines from the tank to oil pump.

Image
The new five lower throttle cables. One is for the oil pump

Image
The custom built power valve cables during the rebuild, these are three sets of the short ones shown.

Re: Just some musings

Posted: Tue Mar 14, 2017 2:45 am
by Alan H
You obviously have far too much time on your hands Allan. You should spend some time elsewhere, like in a bar and talk professional crap with someone.
In fact I'm so concerned about your health, I'll volunteer for the task - just to keep you healthy. So let me know when there's a couple of bikes available in running order (we need something to talk about, right?) and I'll nip over for a few days.

Failing that, your work is, as always 1st class. Keep up the standard mate. :wink:

Re: Just some musings

Posted: Tue Mar 14, 2017 8:02 am
by Suzsmokeyallan
Thanks Mr H, its always great to hear from you, BTW I left a message on your machine.

Re: Just some musings

Posted: Tue Mar 14, 2017 8:32 am
by Alan H
I'll pick it up 'soon' as we are in another country again!