Project Super Sport comments thread - Page 4 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #76 of 86 (permalink) Old 6-2-2019, 11:47 AM
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Yeah the pistons have some sort of coating... POS.
I have a couple of spares if you want them. I also have seals and scrapers if you want them. Not available from Brembo... liability issues. Steve at Bevel Heaven makes up kits for these, doesn't supply scrapers. You can get the scrapers from Honda, GL500 IIRC.



I just did a set of Yamaha TZ calipers. Worst I have seen in a long time, and irreplaceable.
I ended up drilling a hole in the caliper, driving the piston out from the back, then welding up the hole. A bit of filing and paint, looks as good as new.
Another trick is to drill a hole in the piston and thread it. Screw something into that hole to use as a puller.


... I once launched a piston out of a caliper with air pressure, went across the shop and hit my washing machine, cracking the door. $640 later for a new door and seals....


What color are you using for RED? I need some touch up paint.
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post #77 of 86 (permalink) Old 6-2-2019, 5:00 PM Thread Starter
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Good ya got 'em. I cringe when they're about to pop...loud mf'ers, and really dangerous if precautions not taken.
Yeah, they were plenty loud!! Got the attention of almost everyone in the shop when each one went.



I wrapped the piston and caliper in a shop rag so when they went, they didn't go flying. It worked. Farthest one of them went was a couple feet down the work bench.



Just got done with chores for the day....gonna head out to the garage and get the second caliper rebuilt. Then it's on to the master cylinders......sean


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post #78 of 86 (permalink) Old 6-2-2019, 5:12 PM Thread Starter
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Yeah the pistons have some sort of coating... POS.
I have a couple of spares if you want them. I also have seals and scrapers if you want them. Not available from Brembo... liability issues. Steve at Bevel Heaven makes up kits for these, doesn't supply scrapers. You can get the scrapers from Honda, GL500 IIRC.
That's good to know. AFAIK, you can get the Brembo kits from Gotham Cycle and an eBay storefront. I can't remember the name of it. Bevel Heaven is pretty close by to where I live.



I appreciate the offer on the seals and spares. I was able to get my pistons out and they, along with the seals and scrapers are actually in quite good shape. Just covered in scale and jello like old brake fluid. All good after a trip through my ultrasonic cleaner.


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Originally Posted by bitzz View Post
I just did a set of Yamaha TZ calipers. Worst I have seen in a long time, and irreplaceable.
I ended up drilling a hole in the caliper, driving the piston out from the back, then welding up the hole. A bit of filing and paint, looks as good as new.
Another trick is to drill a hole in the piston and thread it. Screw something into that hole to use as a puller.
I didn't want to resort to that level of brute force as I wanted to preserve the Gold Line calipers as much as possible.



TZ calipers? Are you building a TZ? If so....pics plz


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... I once launched a piston out of a caliper with air pressure, went across the shop and hit my washing machine, cracking the door. $640 later for a new door and seals....
oooohhh.....that's 'spensive!! I can relate though. I once worked in a body shop. I finished a paint job and wound up with a really bad run that required me to re-shoot a fender at the very least. I took off my paint hood, and hucked it on the nearest work bench.



All I heard was a really loud SNAP. I looked over at the bench....and there, with a nice big star and crack was the windshield from the very truck that just got a run in the paint booth. It wasn't $649 but I still had to pay for it.


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What color are you using for RED? I need some touch up paint.
I'm actually changing the color so I didn't try to get any red. I got my paint matched (for the color I want) by the House of Kolor rep at my local ACE Hardware.



Aside from trying to get the OEM red from Color-Rite and paying too much for it, I'd check around and see if you have a local HOK rep to do the same for you.



My apologies if I'm not much help in the red paint arena.....sean


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post #79 of 86 (permalink) Old 6-10-2019, 9:21 PM Thread Starter
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BIG box of parts arrived today.......Air Tech delivery!!!!
Too bad I will be away this weekend so the bodywork won't get sanded and primed. I'll be ready to paint in a couple of weeks though. Getting REALLY close now folks......really close.....sean










BTW....we really need a dancing banana smiley.


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post #80 of 86 (permalink) Old 6-19-2019, 10:01 PM
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Originally Posted by Apriliarider View Post
BIG box of parts arrived today.......Air Tech delivery!!!!
Too bad I will be away this weekend so the bodywork won't get sanded and primed. I'll be ready to paint in a couple of weeks though. Getting REALLY close now folks......really close.....sean










BTW....we really need a dancing banana smiley.
Oh nice. Take pics some so we can drool.

Lol on the dancing banana.

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post #81 of 86 (permalink) Old 6-21-2019, 10:39 AM Thread Starter
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Oh nice. Take pics some so we can drool.

Lol on the dancing banana.

Didn't really get anywhere with the bodywork that arrived. Just unboxed it so nothing really to show off. The only thing I did do was I drilled and mounted the new tail section last night.



Mostly to test fit, but also to see what support needs to go under the seat unit where the rider sits. It's a fairly big gap from the frame tubes to the bottom of the fiberglass.



There is a kit available to make it work but I'd anticipated there would be a support issue. I ordered some tank mounting rubber for the later 900SSie thinking that would suffice. I was wrong. Not going to work.



Anyway, here's a shot of the tail mounted with the new saddle sitting in place:
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post #82 of 86 (permalink) Old 6-26-2019, 1:24 AM Thread Starter
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Got a few more things done in the last couple days. Last night I mixed up some JB Weld steel reinforced epoxy repair.



This is not the stuff you get at Walmart in the two tubes. This stuff comes in a double/siamesed syringe type affair that expels the correct amount of each part when actuated.




Using this stuff, I repaired a number of small things that I'd been preparing for. First, I'd ground out the crack in my alternator cover from the inside. After spraying out the newly grooved out crack with brake clean several time and letting it all flash off, I waited until it was all really dry. Probably 20 minutes or so. Then I applied the JB Weld to the groove. Hopefully this seals the crack and I can reinstall the alternator cover back on the engine.


At the same time, I repaired a crack in the crank case from the same area where a chain derailed at some point in the life of the bike. Then, I did the same to one of the speedometer studs that secure the speedo head to the binnacle.



I managed to get the speedo head reassembled tonight, and installed back in the binnacle.




Also painted the speedo needle in orange to make it more visible. I don't know what color it was before but it was white like the tach needle when I got the bike home. It was a royal pain to take apart and get it all cleaned up inside. Then reassembling the lens and bezel onto the speedo head.....royal PITA. It is now done though, so one more step in the right direction...........sean
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post #83 of 86 (permalink) Old 6-29-2019, 12:57 AM Thread Starter
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Finished filing down the JB Weld repair on the engine last night. Came out quite good I think. It will definitely seal up now. I'll have pics up on the PSS thread later this weekend.



Also bought a "Super Sprox" rear sprocket from eBay last week. Delivered today. It's a "hybrid" sprocket if you are unfamiliar. Aluminum center with steel teeth.



Lighter than a steel sprocket but longer wearing than an aluminum one. That will get fitted this weekend also, with the new titanium sprocket nuts I also got on eBay.



Like I wrote above, pics to follow later this weekend..........sean


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post #84 of 86 (permalink) Old 6-30-2019, 12:35 PM
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A long road indeed, your dedication, effort and time/labor/$$ investment will pay off in the end. Just looking at your posted tidbits, its obvious the quality of your work will result in a striking looker and a reliable, fun performer.

Every facet of this thing was either neglected or abused in some way, to some degree.....seemingly everywhere conceivable.

A huge undertaking. My hat is off in a salute.

As an aside, previous owners who allow this disrepair and degradation to happen to any late model classic, especially a Ducati... need to be admonished.
I'm going through similar, though not nearly as in depth, on "the Pile" Triumph 675 in my possession. Sad to see such lame prior "ownership".
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post #85 of 86 (permalink) Old 7-6-2019, 10:27 PM Thread Starter
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Haven't done a great deal this weekend. With Independence Day parties and get togethers nothing got done Thursday. Yesterday, while I did get a few things done, was basically what I normally do on Sundays which was get my stuff ready for the coming week. Today, well....I wrote off most of the day doing badly needed yard work. That, and watching qualifying for the German round of MotoGP.



What I did get done was locate some proper steels for the clutch, so I'm almost ready to get that whole thing together. I have springs and keepers and all that but I still need to verify stack height and de-glaze the steels.



The other thing is't so much something I got done, but rather something I got. I got all the OEM parts to mount the solo tail I have properly from Ducati Omaha today. I'll be test fitting those tonight. Otherwise, just disassembled the "choke" control and separated it from the clutch master cylinder. That should allow me to get it cleaned up and ready for installation.



Not sure how much progress I'll be making in the immediate future. I have to get two bikes ready for the annual pilgrimage to Laguna Seca Raceway for World SBK weekend. I'll probably have to start tomorrow too, as I wanna have plenty of time to get stuff done...............sean


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post #86 of 86 (permalink) Old Today, 1:18 AM Thread Starter
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Back from Laguna Seca and Monterey today. Got home around 2:00 PM after a nice lunch stop at a little place in San Ramon called Fat Maddie's Grille. Pretty cool place, good eats. Kind of a strip mall atmosphere though so nothing special in that department. At least we could keep an eye on our bikes while we ate.....it was San Ramon though so not much to worry about other than the parking skills of car drivers.



As I was in Monterey, nothing got done. Well....nothing on the bike itself. There are however other developments in the works. Parts have been ordered and I'll reveal all once time and developments present themselves in a manner that I can do so. If that all sounds cryptic, it is. There is a surprise brewing that I will reveal when it is appropriate for me to do so.



As World SBK weekend is over for another year, I now have more time to focus on things and get more jobs done. I have not, as yet set a new time table for completion. Just later this year. No rush at all.



Unfortunately, I have to divert a significant sum of project money to a home project that has needed doing for the better part of 2 decades. Sometime in the near future I'm ordering several yards of concrete and having a patio poured in front of my house. Probably somewhere on the order of 5 or 6 yards at least. Maybe more. Needless to say, that will put a huge damper on the project with regard to buying needed parts......sean


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