J - Refresh

[tlc]

This is the last picture I have of my J1 on the road.




It was by this point making a rather unsatisfactory ticking noise from the engine so I knew I would have to get it sorted by taking the engine out sooner or later. It (the engine) was also looking rather tired with crud underneath and paint flaking here and there.


At about this time I was progressing with my 1100R project. I needed space in the garage so took the bike to work to store in my container. This was not the most sensible decision as although weather tight containers sweat. Everywhere that was thin on finish ended up either furry or rusty. I brought it back home once I had the space as I needed to borrow some bits here and there so I put the bike on the bench and took what was required.
I have been collecting parts lately which some of you will know about and today have started the strip down in earnest. There will be a slight twist at completion but nothing that will detract in any way from the absolute catalogue standard nature of this "survivor". During the strip I will be noting the recall fixes that I think were missed on this early bike. As it is frame 2600 it falls within all the recalls, some of which I can see and some I'm guessing at.

Anyways, here are some pictures that show the wear it has suffered and which will also come in handy for reference when I put it all back together.

















I have a deadline of mid '17.

[tlc]

I started work on the battery box.At 12mm long the broken bolts had hardly anything to grip. I had to be sure I could get them out without mashing the protruding part.Having access to Oxy/Acetylene comes in handy nearly every day at work.
It made short work of the broken bolts.







These bolts are NLA even where I have bought from before. They are non upset and have a captive spring and plain washer. They also have a number 4 on the head. Luckily I had some in stock which should clean up okay.





I moved on to the Igniter box which had suffered some furring. The flat parts were easy to restore, simply a gentle gong over with a scothbrite pad. They always did have that finish anyway so a couple of passes with my soft / fine pads had them looking right.
The castings though needed another method. Some time ago I bought this which is like a giant tooth brush. I only have the bristle head but other more abrasive heads are available.

[chrisu]

i assume its getting a rebore too.

good work chris

[tlc]

I will see when I get there Chris.

Just tidying my work space today before yet another evening meeting and noticed this which I have never seen before.
Any clues anyone?

[Al]

Mine has 64 but on the RHS version of that bracket.

AL

[tlc]

Trying to do what I can without spending any money today I used the detailing brush on my wheels.
The ingrained brake dust came out easily from the painted parts as well as the textured finish of the spoke sides.
See what you think.

[Ginger Bear]

They look as good as new........

[Is Vic There]

The wheels have come up a treat, nice one.
If you can't fin a number 4 bolt with captive washer I'm sure I have one.

[tlc]

Thanks Ian. I did find one but Mikey will need to work his magic on it.

[jphaynes669]

Good work so far chris,

[tlc]

This is now becoming painfully slow.
A couple of things have conspired to cause delay. First off was the need to replace my works van. That means transferring all the kit from one to another. This was easier than the last time but there are still some jobs to do.
Thankfully I also got a bit busier at work. These things don't pay for themselves.

The bike is now well stripped but I wanted to make a start on sub assemblies before removing the engine so to that end my first completed job is the rear wheel.
Mikey worked his magic on these parts. Just new zinc plate on sympathetically polished components and RD Cox of Reading cleaned up the sprocket hub.
Interestingly the original sprocket was good so I just cleaned it before Mikey had it. I do have an nos one in stock though.

[LeeJackson]

Looking good Chris! Sure it didn't look that good new..

[Richard L]

Super work there Chris . I can fully understand the attention to detail and perfectionism , but I know that if I did it , the bike would never go anywhere ever again !
Richard

[Kev1R]

The wheels are fantastic - I need to try something similar with mine.
So the tool you used was just a giant tooth brush - Is it merely hand held? - ie not an electric giant tooth brush

I suspect the main factors here are patience and elbow grease

Well done anyhow - great results

[Julian_Boolean]

Nice one, I've set myself a similar date for getting my J running and rideable, though I think the only bits of mine that are actually J are the frame, crankcases, battery box, rear mudguard and maybe the petrol tank and tail piece.