The customer-supplied parts are… way too many… so we’re in full assembly mode.
We’ll replace the step, but the silencer is temporary for now.
Let’s start with the correction work. (Actually, this was supposed to be near the very end.)
I made it from Delrin,
with two flat faces so it fits perfectly at 60.5 mm and can be held securely in a vise.
It was so thin and flimsy that it sprang right back.
I machined a collar that fits perfectly inside the inner tube,
and mounted it on some scrap material that looks like it was used before.
It’s a strategy of surfacing while pushing.
The XJR step plate ribs aren’t in there either, so we have plenty of room.
Next I want to check around the step area.
I also replaced the engine hanger and slider.
Pretty gnarly, huh?
I carefully filed down the scraped fins. Glad they didn’t crack.
I got the digital gauge power from a connector.
Yamaha wiring diagrams are so hard to read when you’re not used to them.
The shape is slightly different, so the brake hose bracket won’t work.
I’ll rip it off with a spot cutter. You really should keep a spot cutter on hand.
Hmm, is it this time? Yeah, it must be…
I went a bit generous on the safe side, and it turned out to be the right call.
I think position adjustability is really important.
I can’t really recommend just raising or lowering it because it contacts.
I think it’s more fun to be able to adjust it when you’re riding—”this spot! or maybe a bit more!”
What happened here?
Fluid maybe? I peeled it off and touched it up with paint pen.
When I disassembled the meter, it was in pieces. I extracted just the speedometer and transplanted it into the new meter.
I was amazed at how it comes out from the front.
No touching the harness area either! It comes out clean.
Brembo Corta Corsa. This mode… actually… hmm.
I made a master tank (large) bracket in a way that’s not a hassle.
I really struggle with handlebar fitment and cable routing.
I recently upgraded to version 2.
3M Anti-Slip Tape Type F
I cut it to grip length and then cut it in half to use.
If you use the same length as now, it’ll look too cool-guy, so watch out.
Putting this on hold for now.
