A lot of hoses, electrical connections and other small pieces have been installed now. It is now clear that it is vital to take lots of pictures during disassembly, those are coming in handy now. The rear frame will be fully mounted as soon as the rear fairing and footrests are finished. For now the …
Category Archives: RS 250 Workshop Diary
Brake disassembly
It was obvious: M8 screws with 5 mm hexagon socket, where the tool cross-section is smaller than the cross-section of the screws. This could not end well. Actually, I only wanted to disassemble the calipers, clean them and reassemble them with new screws to keep the look uniform on the machine.
Front Fork
When disassembling the front fork it turned out that the crumbs on the spars were not crumbs at all but rust spots where the chrome layer already had holes. So the fork legs are scrap.
Installing Cylinder Heads, Cooling and rear Frame
For the assembly of the cylinder heads I had to order new expansion bolts and a few other small parts, these should not be reused after disassembly. Unfortunately the copper gaskets at the nuts at the cylinder head are not according to standard, so the old gaskets were brushed off and installed again.
Renewal of rear suspension bearings
At the rear suspension all needle bearings had to be replaced, because the old cages were full of water for years. Therefore the cages were corroded when they were removed. For the installation of the needle bushes I made a suitable bolt on the lathe to countersink the bushes so that the shoulder for the …