First I winched the bike into the air from brackets I have fitted in the garage rafters for just such an occasion. Once the front was off the ground at about the attitude of the bike if it had wheels, I was able to kick down the main stand. Given that swing arm and rear wheel were fitted, the bike just sat there resting on the back wheel. The sling was removed. Next I offered up the stanchions. It was going to be a tight fit through the lower yolk. I sprung the yolk for each leg in turn. This made slipping the stanchion through very easy. As soon as the yolk was allowed back to its natural position it gripped the stanchion sufficiently to prevent it moving. Next on was the front wheel. Without springs in the stanchion it is easy to move the stanchions to the right position to offer the wheel pin through the bottom of the stanchion and through the wheel hub. As usual the spacer meant you really need a third hand so that you push the pin, hold the spacers and position the other stanchion. With a bit of faffing about I managed it. Then I dropped in the shorter set of springs in the stanchions and did up the top caps. That was the front mocked up.
The next job was to fit the rear sub-frame and suspension. Whilst rummaging for the sub-frame bolts I found the clutch actuating pin. More about that later. I fitted the sub-frame with the bolts provided and than tried the suspension units. I could not find the right bolts for the top or bottom mounts. I settled for some that were a little too long. I will have to get the correct once before it goes on the road but it will do for now. Having the chassis rolling means I can move it about easily and it means I have less things lying about the garage.
In my hurry to fit the swing arm I over looked that the clutch actuating pin was not fitted. The swing arm covers the back of the gearbox where the clutch is operated. The clutch pin goes right through the gear box so is about eight inches long. To fit it the swing arm has to be removed. It is not a big job once the suspension is fitted. I just whipped off the back wheel and took out the swing arm pivots and eased the swing arm and bevel box backwards. The suspension legs supported the weight and limited the amount of movement. Once that was done it was a five second job to position the pin. Whilst is was there I fitted the associated thrust bearings and actuator arm. I adjusted the slack out and squeezed the actuator arm. It moved freely and I could feel the clutch springs responding. I fitted the universal joint boot whilst he swing arm was out and tightened up the battery carrier mounts. The swing arm was refitted as was the rear wheel. In refitting the rear wheel I noticed some movement round the axle. Close inspection showed the bearings were damaged or worn out. Something else for the parts list.
Now the bike looks like this:
This will be the biggest leap forward. From now on it will small steps as missing parts are sourced. I had another rummage and tidy up of the contents of the boxes that came with the bike. I am still trying to assess what is missing. I found home round the garage for the bits and pieces that will not be fitted for a while. I even had a look at the wiring loom. It is a monster and I can not find the ignition switch. I have the key!?
