My long time friend the pransing horse

Who are you? Why are you here? Tell us about yourself!

Moderator: Moderators

User avatar
Tioli
Champion
Champion
Posts: 756
Joined: Mon Jan 16, 2012 9:12 pm
Bike: ty175je , KDX/KX ,,,
Location: Tas

Re: My long time friend the pransing horse

Post by Tioli »

Using a bigger cable tie than the one they provide will fill the grove and stand proud of the material.
image.jpg
image.jpg (106.5 KiB) Viewed 10687 times


Now the left side is a different story. The guide is also used to locate the brake line so ti had to stay. Problem is the saver has no way to be located over the outer tube.
image.jpg
image.jpg (117.13 KiB) Viewed 10687 times


My attempt to fix this by cutting sections out of the saver hasn't seemed to work.
image.jpg
image.jpg (109.43 KiB) Viewed 10687 times


Sort of works but dirt could get in under the slits so what's the point of having it.
image.jpg
image.jpg (162.11 KiB) Viewed 10687 times


image.jpg
image.jpg (138.3 KiB) Viewed 10687 times
hindsight is a terable way to learn I'd rather be gifted
User avatar
Tioli
Champion
Champion
Posts: 756
Joined: Mon Jan 16, 2012 9:12 pm
Bike: ty175je , KDX/KX ,,,
Location: Tas

Re: My long time friend the pransing horse

Post by Tioli »

image.jpg
image.jpg (103.95 KiB) Viewed 10643 times


For some reason Kawasaki decided to run the brake lines up the front. I seem to remember reading once that Kawasaki did not want to pay Honda the patent royalties. And that's why they call it CR style when the brake line runs straight up from the calliper and through on the inside. How long do patents last for 10 years?
image.jpg
image.jpg (138.9 KiB) Viewed 10643 times


image.jpg
image.jpg (125.99 KiB) Viewed 10643 times


If I take that off You have to do some thing about locating the brake line.
image.jpg
image.jpg (139.22 KiB) Viewed 10643 times


Seems the best way is to make a stay for the line at the top of the guarde.
image.jpg
image.jpg (122.18 KiB) Viewed 10643 times
hindsight is a terable way to learn I'd rather be gifted
User avatar
Tioli
Champion
Champion
Posts: 756
Joined: Mon Jan 16, 2012 9:12 pm
Bike: ty175je , KDX/KX ,,,
Location: Tas

Re: My long time friend the pransing horse

Post by Tioli »

If I'm going to make a line clamp on the protector than its probably going to be glued.
image.jpg
image.jpg (112.98 KiB) Viewed 10630 times


A little experiment to see what stickers best tells me they are all the same.
image.jpg
image.jpg (99.03 KiB) Viewed 10630 times


A few lines no a cut of section of nylon rod as a guide
image.jpg
image.jpg (80.39 KiB) Viewed 10630 times


image.jpg
image.jpg (88.83 KiB) Viewed 10630 times


I don't trust my ability to cut straight lines so I follow the line round the rod.
image.jpg
image.jpg (164.65 KiB) Viewed 10630 times
hindsight is a terable way to learn I'd rather be gifted
User avatar
Tioli
Champion
Champion
Posts: 756
Joined: Mon Jan 16, 2012 9:12 pm
Bike: ty175je , KDX/KX ,,,
Location: Tas

Re: My long time friend the pransing horse

Post by Tioli »

image.jpg
image.jpg (178.84 KiB) Viewed 10185 times


Clean it up with a bench grinder
image.jpg
image.jpg (155.29 KiB) Viewed 10185 times


Check that you are pressing evenly.
image.jpg
image.jpg (154.34 KiB) Viewed 10185 times


Stop when you are roughly there.
image.jpg
image.jpg (136.91 KiB) Viewed 10185 times


Now the next cuts.
image.jpg
image.jpg (204.58 KiB) Viewed 10185 times
hindsight is a terable way to learn I'd rather be gifted
User avatar
Tioli
Champion
Champion
Posts: 756
Joined: Mon Jan 16, 2012 9:12 pm
Bike: ty175je , KDX/KX ,,,
Location: Tas

Re: My long time friend the pransing horse

Post by Tioli »

image.jpg
image.jpg (134.49 KiB) Viewed 10185 times


Round off the edges to make it look nice.
image.jpg
image.jpg (143.25 KiB) Viewed 10185 times


image.jpg
image.jpg (141.73 KiB) Viewed 10185 times


Problem is the back of the block is flat.
image.jpg
image.jpg (78.28 KiB) Viewed 10185 times


Out with the marking pen and file it down in the centre to the right curvature
image.jpg
image.jpg (185.04 KiB) Viewed 10185 times
hindsight is a terable way to learn I'd rather be gifted
User avatar
Tioli
Champion
Champion
Posts: 756
Joined: Mon Jan 16, 2012 9:12 pm
Bike: ty175je , KDX/KX ,,,
Location: Tas

Re: My long time friend the pransing horse

Post by Tioli »

image.jpg
image.jpg (208.05 KiB) Viewed 10130 times


image.jpg
image.jpg (77.7 KiB) Viewed 10130 times


image.jpg
image.jpg (67.75 KiB) Viewed 10130 times


Cut a strip of Stainless steel out of a old hot plate cover.
image.jpg
image.jpg (139.26 KiB) Viewed 10130 times


The brake line is 11mm and this bolt is 10 so bend the strip round and clamp down.
image.jpg
image.jpg (152.57 KiB) Viewed 10130 times
hindsight is a terable way to learn I'd rather be gifted
User avatar
Tioli
Champion
Champion
Posts: 756
Joined: Mon Jan 16, 2012 9:12 pm
Bike: ty175je , KDX/KX ,,,
Location: Tas

Re: My long time friend the pransing horse

Post by Tioli »

image.jpg
image.jpg (168.33 KiB) Viewed 10129 times


The line clamp on my Yamaha and the bottom one on the Kawasaki are 15mm centre to centres so I take it that's a standard if I ever wanted to get a aftermarket clamp.
image.jpg
image.jpg (167.4 KiB) Viewed 10129 times


Mark drill and bolt.
image.jpg
image.jpg (154.3 KiB) Viewed 10129 times


Mark it out for where it's going to sit.
I chose that spot because it's the same thickness as further down and if the screws I'm going to attach it with sit proud the guard only moves up from there.
image.jpg
image.jpg (134.82 KiB) Viewed 10129 times


mark the block where I'm going to drill some holes for screws. You can see through the plastic and mark the guard and drill holes and countersink it.
image.jpg
image.jpg (90.82 KiB) Viewed 10129 times
hindsight is a terable way to learn I'd rather be gifted
User avatar
Tioli
Champion
Champion
Posts: 756
Joined: Mon Jan 16, 2012 9:12 pm
Bike: ty175je , KDX/KX ,,,
Location: Tas

Re: My long time friend the pransing horse

Post by Tioli »

Find some screws.
image.jpg
image.jpg (160.32 KiB) Viewed 10129 times


Drill some holes just smaller than the screws and hope it all lines up straight.
image.jpg
image.jpg (85.65 KiB) Viewed 10129 times


Screwed and glued. I'm not confident that superglue is the best choice?
image.jpg
image.jpg (152.26 KiB) Viewed 10129 times


Screw heads are sunk in enough.
image.jpg
image.jpg (74.33 KiB) Viewed 10129 times


image.jpg
image.jpg (100.51 KiB) Viewed 10129 times
hindsight is a terable way to learn I'd rather be gifted
User avatar
Tioli
Champion
Champion
Posts: 756
Joined: Mon Jan 16, 2012 9:12 pm
Bike: ty175je , KDX/KX ,,,
Location: Tas

Re: My long time friend the pransing horse

Post by Tioli »

image.jpg
image.jpg (114.37 KiB) Viewed 10128 times


Now I just have to wait for a new fork wipe.
image.jpg
image.jpg (150.27 KiB) Viewed 10128 times
hindsight is a terable way to learn I'd rather be gifted
CLO
C grade participant
C grade participant
Posts: 20
Joined: Thu Jan 07, 2016 3:29 am

Re: My long time friend the pransing horse

Post by CLO »

Looking good. I would agree that superglue wasn't the ideal glue, but those screws should take care of it.

Have you been riding a lot and had a chance to check to see if your piston mods have helped?
Post Reply