Strip - rebuild

[abraxas]

Some of you may recall my problem with the cracked frame.

Sadly the weld hasn't lasted, but it was a possibility at the time, since the weld was only done on one side. We suspect that one of the ribs on the inside on the frame still had a crack, which spread.

So most likely month end, i'll be taking a week off work. Hopefully i can strip the frame over the weekend, get it to the welder monday morning. Tuesday i should be able to collect, then spend the rest of the week rebuilding.

Since i am stripping the frame out, and the bike is on 100 000km, i think it would be a good idea for a nice overhaul. Immediate on my list are the swingarm, and engine mounts. Steering head i did recently, but needs to be retightened etc.

So a few questions:

What else should i be looking at?
Fork oil: should i change? If so, how?
Removing the engine: what should i NOT do, or what should i be careful of?

This is just a brainstorming thread, trying to get my head straight before i do something really stupid (highly likely ;-) )

 

[TownsendsFJR1300]

Take lots of pictures, lable wire connectors (both ends "a" to "a", etc).

The engine should drop straight down after unplugging, removing exhaust and unbolting. I believe you can leave the throttle bodies on.

I'd also download the shop manual (available on this forum) and have it handy for torque values, etc....

I would probably, if possible remove and re-install in the new frame one section/part at a time. It may take a little longer but doing just the front end at a time over to the new frame BUT would be less daunting than stripping out the entire brike frame and having a garage full of parts (what goes first/next?)

Good luck...

 

[abraxas]

Aha ... dude, my manual is in 2 big files, the printed papers in plastic sleeves so i don't make them dirty while working!!!! (highly recommended btw).

Yes, pictures ... lots, and masking tape, and a black marker, right!!!

I think you misunderstand though. I'm not replacing the frame, just removing it to re-weld, both sides of the crack, and probably re-inforce it.

So i probably won't remove everything, leave the harness in place and such.

I could JUST drop the engine, but figure that once you've done that, you can at least gain access to other places.

Thanks for commenting!

 

[TownsendsFJR1300]

Yea, just re-read your post, missed it... Anyway, good luck with it.

BTW, I'd disconnect the battery and ECU just to make sure your don't fry anything....

 

[RJ2112]

To quote one of FJR's favorite topics..... while you have access to all the connectors, pull them apart and add dielectric grease. No such thing as a too well protected connection.......

 

[TownsendsFJR1300]

To quote one of FJR's favorite topics..... while you have access to all the connectors, pull them apart and add dielectric grease. No such thing as a too well protected connection.......

Excellent point!