Honestly, oil-cooled bikes are so reassuring to work on. I find myself getting a bit sentimental about it.
We’re familiar with these, so work gets done in the expected timeframe. There are hardly ever any surprises.
*Today I had to chisel out a couple of spots, but they came off easily, so all good.
I think peace and quiet is best in all things.
Today I’m using a rear caliper as a substitute.
I’m changing the rear disk to a Sunstar LR023.
The original is 6mm, so it doesn’t appear in the Sunstar compatibility chart.
The Bandit 1200 has nearly the same weight and the same caliper, and it uses 5mm, so rest assured.
That said, 6mm might be rare or a product of its era.
The wheels are Gale Speed, and one of those bolt-like fasteners that came with them was seized solid, so I had to chisel it out.
Have you ever run into a situation where you can’t assemble something today?
I had a Kawasaki disk bolt in stock. The shank and step were identical, but the head diameter was larger, so I ground it down, applied Guncoat, and just barely made it work.
Various parts are coming together with a sharp finish.
I’m brushing the parts with the mindset of Italian craftsmanship.
The axle was running a bit off-center.
It’s inexpensive, so I’ll go ahead and replace it.
61411-40C00, ¥530 before tax.
It’s coming back to life bit by bit.
It’s been a while since I’ve seen a diaphragm this swollen. Quite a surprise!
Now to replace the caliper… or should I?
Hmm, it’s a bit scary, so I’ll go ahead and take care of it.
At full stroke, there’s barely any clearance between the silencer and the swingarm.
I was impressed at how well it works out.
It was a direct fit, so I installed a stepped plastic spacer to secure it.
All that’s left is to bleed the clutch master and do the inspection.
Progress
✓ Carburettor disassembly and cleaning
✓ Intake manifold replacement
✓ Front caliper cleaning, pad replacement, and installation
✓ Clutch master removal
✓ Radial clutch master installation
✓ Master tank bracket fabrication and installation
✓ Rear caliper disassembly in progress
✓ Carburettor installation
✓ Synchronization and PS adjustment
✓ Throttle cable and band replacement
✓ Spark plug replacement
✓ Rear caliper replacement
✓ Rear pad installation
✓ Rear fluid bleeding, diaphragm replacement, and pan head screw replacement
✓ Rear disk replacement with LR023 & Kawasaki OEM modified bolt used
✓ Chain adjuster replacement
✓ Rear components Guncoat painting
✓ Chain and swingarm cleaning
✓ Carbon rear fender clearance work and stepped spacer installation
