Author Topic: The restoration of CJ (Read 20982 times)

Fat Rat · « **on:** June 06, 2019, 16:39:12 »

A while ago, a nice fella named Patrick joined this site to offer a free DL1000

The 2004 bike belonged to his late brother who was known as 'CJ'. Patrick asked me to name the bike accordingly.

This week I headed down to Hove to meet Patrick and collect the bike. It had two flat tyres (one without a valve) and everything was pretty rusty and seized because the bike had sat in Patricks' garden for some years. I managed to get some air in the rear tyre and a few squirts of oil on the chain and the thing was moving, up the ramp and into my Van.

This is not going to be a quick restoration, in fact it could get cut short at any time if I discover the engine or gearbox are not serviceable. The level of restoration will also depend on how many miles are on the bike (unknown at the moment).

The first task is to wire in a new ignition switch. The top yoke is broken so it looks like it may have been stolen or attempted stolen at some point. Then I need to take the tank off to see if there is any rust inside (likely). Once that is clean, I will take the fuel pump assembly apart and replace the paper strainer. Then I will drop the oil and replace it. Then, only then, will I attempt to turn the engine over.

If everything moves nicely and the gears engage then I will start pulling her apart. At a glance she is going to need all new bearings, chain and sprockets, a top yoke, forks re-chromed or new stanchions. The caliper pistons and seals will need replacing as will the brake hoses. I have already removed the nest from under the seat that was obviously the home for a family of rodents and I have evicted several hundred spiders

Other than that, a wipe down with a damp rag should do the trick.

MartinW · « **Reply #1 on:** June 06, 2019, 16:48:13 »

x 100

Fat Rat · « **Reply #2 on:** June 06, 2019, 16:56:11 »

I thought I would give her a bath before taking into the Man Cave.

Tusker · « **Reply #3 on:** June 06, 2019, 17:13:09 »

FR, just remember, she will be worth it !!! do her proud ..

TLPower · « **Reply #4 on:** June 06, 2019, 18:37:23 »

Brockett is the main man for sorting any poor running issues. Normally I'd endorse Mr Nick but he's a little occupied at the moment.

A wonderful and quite poignant project all the same.

UK_Vstrom650 · « **Reply #5 on:** June 06, 2019, 18:38:03 »

Good stuff FR. Looking forward to the updates

Barbel Mick · « **Reply #6 on:** June 06, 2019, 18:51:57 »

All the best with the restoration.

Fat Rat · « **Reply #7 on:** June 06, 2019, 20:35:18 »

As the bike needs a new ignition barrel (and has no keys), I need to change the fuel cap and the seat lock too. The breakers want up to £80 for a set of locks that are 17 years old

So, I took a punt and ordered a set from China for £29 delivered. Can it really be worse than an old worn set?

Fat Rat · « **Reply #8 on:** June 06, 2019, 20:38:39 »

By the way, does anyone see the irony in the fact that the water pump housing isn't corroded

MartinW · « **Reply #9 on:** June 06, 2019, 21:06:24 »

That will be because the Silver Frame versions were made properly .....

StromGeeza · « **Reply #10 on:** June 06, 2019, 21:15:00 »

Those keys would make good meat skewers...

Mr Nick · « **Reply #11 on:** June 06, 2019, 23:10:18 »

Good luck with that job FR - hopefully you can do CJ's memory proud.

I bought a lockset of Chinese origin for the SV for about the same cost and found them to be fine.

Fat Rat · « **Reply #12 on:** June 06, 2019, 23:13:01 »

Thanks, good to know

NTBooth · « **Reply #13 on:** June 07, 2019, 07:52:14 »

Looks like a great project!

Personally, a quick spray of wd40 and I reckon it would be in better nick than some of the bikes I've had. Get it ridden - would be a good commuter

Gassoon · « **Reply #14 on:** June 07, 2019, 09:10:06 »

Great stuff, Patrick and FR - enjoy the rebuild, and

mrp192 · « **Reply #15 on:** June 07, 2019, 10:42:26 »

Looking forward to the updates. I would think there is a good chance most bike manufacturers obtain locks and many ancillary components from China in the first place.
If the keys look a bit flimsy you could always replace them at a Timpsons or similar.

Fat Rat · « **Reply #16 on:** June 07, 2019, 14:34:24 »

Good grief, I could have died!!

TLPower · « **Reply #17 on:** June 07, 2019, 14:46:54 »

That's dinner sorted then.

Fat Rat · « **Reply #18 on:** June 07, 2019, 14:49:34 »

We are going to freeze them and serve them as a speciality from the Dragon Wagon at the August meet. That assumes that they don't wake up first, I think the first two blows with the 4" x 2" may have only stunned them

Rusty Nuts · « **Reply #19 on:** June 07, 2019, 15:23:14 »

Yummy. No arguing about who gets a leg, then.