72 Combat Proddy Build

Re: 72 Combat Proddy Build- It begins...


Brand new set of brake shoes. Oh well, the old ones are still serviceable...


I clipped off the wire tie from the Boyer. The wires are nicely epoxied down to the board. I assumed the wires from the harness to the points cover would be included with the Boyer kit... silly me, they are on the stock harness... which we all know, I don't have. So I would like to source the right color wires but until then I'll stick something on there.

Re: 72 Combat Proddy Build- It begins...

I have many feet of Blk/Wht & Blk/Yel wires left over from clipping the excessively long Sparx wires.

Postage would cost more than they are worth, though...

Re: 72 Combat Proddy Build- It begins...

grandpaul said:

I have many feet of Blk/Wht & Blk/Yel wires left over from clipping the excessively long Sparx wires.

Postage would cost more than they are worth, though...

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Well, the other choice is to buy it from British Wiring. That's going to cost more than postage.

I'm not really cramping on the wires. They will be covered in heat shrink so no one will even know what colors they are.

Re: 72 Combat Proddy Build- It begins...

Figure out whatever other loose ends you need and we'll send it all at once.

Re: 72 Combat Proddy Build- It begins...

grandpaul said:

Figure out whatever other loose ends you need and we'll send it all at once.

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I think I might be the biggest loose end in this whole project. :mrgreen:

Re: 72 Combat Proddy Build- It begins...


Handlebar switches on.


Did a preliminary run of the clutch cable. I'll scour the archives to see if I can find the best route.

More good news coming soon. Well, it will be after I get a gearbox sprocket nut that works...

Re: 72 Combat Proddy Build- It begins...

I'm sure i have a proper gearbox nut. I'll re-check in a few minutes. I can pack it with some color-coded wire...

Re: 72 Combat Proddy Build- It begins...

grandpaul said:

I'm sure i have a proper gearbox nut. I'll re-check in a few minutes. I can pack it with some color-coded wire...

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I'm just going to get a new one from Old Britts. It's not expensive but I was just waiting to get enough of an order together to make it worth while. Thanks for the offer!

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Hoping for a couple shipments of parts this week.

Best case scenario for the weekend is getting the bike off the bench... just enough to sit on it and put it back.

Re: 72 Combat Proddy Build- It begins...


Clutch perch painted.


Installed. Need a clutch cable adjuster.

Re: 72 Combat Proddy Build- It begins...

Two packages just showed up. I have kid-duty or else I'd be out there putting parts on.



Lucas headlight, a two position and a three position headlight switch, headlight bulb holder, warning light bulb holders, and most importantly... the serial number plate with rivets.


The RGM belt drive kit.


Handlebar clamps (with more SS bolts), sleeve gear, clutch adjuster, headlight spacer, gearbox sprocket nut, brake shoes, axle spacer, rear brake springs.

If you've been following the gearbox sprocket nut horrors here and elsewhere you know that I still haven't been able to get it on. I'm assured that worse case this nut and sleeve gear will work. I'm hoping it doesn't come to that drastic of a solution. This nut looks different from other ones I've haved. I'm hopeful.

Re: 72 Combat Proddy Build- It begins...

rgm-belt-illustrated-install-guide-t6750.html

Belt drive adventures.



Gearbox Sprocket Nut finally installed but not final torque. Need drive chain for that.


And the handlebar clamps. Sure are better than the zip ties that were holding it. :mrgreen:

Now if I get the rear axle and try to get the bike off the bench it won't fall over and kill me when I grab the bars...

Re: 72 Combat Proddy Build- It begins...

Is it time for this now?

Re: 72 Combat Proddy Build- It begins...

pvisseriii said:

Is it time for this now?

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Not yet. :mrgreen:

Pretty sure all I'll do is get the big wrench and tighten it down. I know what 80lb/ft feels like.

Re: 72 Combat Proddy Build- It begins...

I picked up my rear axle and nut today. I thought I'd be getting it tomorrow but my schedule flopped and I took advantage of it.

It took me a while to fit the rear wheel. Not sure why it fought me so much. I, of course, was victorious in the end. To celebrate said victory I decided to roll the bike off the bench for the first time. I did have rear brake and the wife to help so it was uneventful until I discovered the front rotor studs hitting the front fork and not allowing the wheel to turn. That was easily rectified.

First the video and then pics.

[video]http://www.youtube.com/watch?v=UVW0lDZ1uG0[/video]







My list now is something like:

Tidy up wiring harness.
You know about the belt drive.
Rear chain.
Finish the front brake (I have an old hose but I'd rather use stainless). I still need to install the SS pucks, and I'm missing the clip and rubber diaphram for the master cylinder.
Carbs are empty so I need all new parts there.
Headlight, need a rim and finalize the bulb. Also finalize the mount.
Then wheels and tires. I think I mentioned it before but one tire says Great Britain on it and the other... Republic of Ireland. :mrgreen:

As soon as I get through one list of tasks there are plenty more waiting.

Re: 72 Combat Proddy Build- It begins...

I think I mentioned it before but one tire says Great Britain on it and the other... Republic of Ireland.

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Wow! How old are those tires?? It's been a lot of years since Dunlop built motorcycle tires in the UK! Be careful on those that rubber has to be awful hard and slippery!

Re: 72 Combat Proddy Build- It begins...

Ron L said:

I think I mentioned it before but one tire says Great Britain on it and the other... Republic of Ireland.

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Wow! How old are those tires?? It's been a lot of years since Dunlop built motorcycle tires in the UK! Be careful on those that rubber has to be awful hard and slippery!

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Don't worry, they are just on there to roll the bike around.

The goal is to send the wheels to CNW for new shouldered alloy rims and new tires.

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If you do, you won't regret it. I was amazed when my wheels came, and I opened up the box- 100 times better than I thought they would turn out.

Re: 72 Combat Proddy Build- It begins...


The fuse for between the Podtronic and the battery.


Installed.


I picked up some keys. Amazingly they were pretty standard size. The larger one is 1/4x3/4 (got this at a Carquest for $.90) and the smaller one was 5/32x5/8 which surprisingly I got at Home Depot (2 for $.60). Saved about a thousand dollars from buy them from a dealer.

Re: 72 Combat Proddy Build- It begins...


I got the headlight attached (finally). I needed the spacers and I found some decent alternatives (for this project on the semi-cheap). I want to find something better than the regular bolts I have now but they are cheap and they hold it on, which is good enough for now. I did spring for some nice chrome washers.


The right size spacer...


Which is actually a shaft collar. I think it's just zinc plated but it looks nice (just as long as I keep the set screw facing away), I think they were $.30 ea. :mrgreen: