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Project Balius makeover

Discussion in 'Your 250cc Projects' started by Minimata, Mar 20, 2017.

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  1. Minimata

    Minimata Active Member

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    Blooming auto correct! Meant say I have sussed out not Sussex.....
     
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    Minimata, Apr 20, 2017
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  2. Minimata

    Minimata Active Member

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    Balius update.

    Taking off hugger mounts and wondering if the mount below needs to be retained as it performs some other function ? Shonky bit of metal spoiling my lines!

    image.jpeg
     
    Minimata, Apr 28, 2017
    #22
  3. Minimata

    Minimata Active Member

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    And another thing.....
    Anyone dissected a Balius silencer and can tell me what can done with a split outer skin and crumbling inside? Amputation seems only option but as hi up link pipe as poss.... Drilling out rivets and removing outers may show me what score is ?

    image.jpeg
    image.jpeg

    Ignore forehead and lobotomy scars at bottom of photo........
     
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    Minimata, Apr 28, 2017
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  4. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I'm guessing that there;'s a split under the tape somewhere ?
    That is just a welded seam in the second picture

    You might get away with having the split welded back together with a Mig or Tig if it's not too bad, then just cleaning the perforated pipe and repacking it, but won't know till it's apart
     
    my67xr, Apr 28, 2017
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  5. Minimata

    Minimata Active Member

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    Cheers mate. All I need to do now is get corroded nuts off manifold studs.........that usually hurts as stuff shears off........maybe just split nuts from start?
     
    Minimata, Apr 28, 2017
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  6. kiffsta

    kiffsta Senior Member

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    Try some wd40 / inox and let them soak in a bit
     
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    kiffsta, Apr 28, 2017
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  7. Minimata

    Minimata Active Member

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    Cheers Kifsta. Any thoughts on the removal of the inner hugger mount from swing arm and anything else it may be there for ? See photo above..
     
    Minimata, Apr 29, 2017
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  8. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Does it hold the chain guard on as well as the hugger ?
     
    my67xr, Apr 29, 2017
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  9. Minimata

    Minimata Active Member

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    Yes. It was an integrated chainguard and hugger.........nasty.

    Shouldn't be an issue removing mount if running without it?.. May make a small guard to mount using other points that will remain
     
    Minimata, Apr 30, 2017
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  10. Minimata

    Minimata Active Member

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    Ok who hid the lights on switch ? I have a main and high switch but no lights on switch.....what's with Kwak ? I can get onto high beam but how do you get main ?

    I know I am being a numpty here ........
     
    Minimata, Apr 30, 2017
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  11. kiffsta

    kiffsta Senior Member

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    If it is like the zxr, the head light comes in once the engine is started , no on or off switch
     
    kiffsta, Apr 30, 2017
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  12. Minimata

    Minimata Active Member

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    Back on the forum with some Balius updates. Polished swing arm and pimped shock. My other plan is to weld a tab onto pipe at footrest mount location so I can hang it from here and remove existing hanger/rear pegs.

    image.jpeg

    Forks getting the treatment next. Just wondering if a bit early to start playing with fork oil weight or changing oil before I have test ridden suspension ? Any good tweaks for Balius front and rear suspension ?

    image.jpeg
     
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    Minimata, Jun 6, 2017
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  13. Minimata

    Minimata Active Member

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    Pleased with fork polishing results. Just need to fit new dust caps with when they arrive...

    IMG_0037.JPG
     
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    Minimata, Jun 8, 2017
    #33
  14. kiffsta

    kiffsta Senior Member

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    Nice work, what did you use to get that finish ?
     
    kiffsta, Jun 8, 2017
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  15. ZXR Kawasaki

    ZXR Kawasaki Member

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    Gold valves work in the forks very well in my track balius.
     
    ZXR Kawasaki, Jun 8, 2017
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  16. Minimata

    Minimata Active Member

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    Thanks!

    Finish requires following stages:
    • Rub down with wet and dry in wet mode. Use 800 grit to get grime off then 1200 grit.
    • Polish with rotary mops using two grades of compound medium and fine. I mount drill horizontally in vice and move the fork leg through the mop.
    • Finally buff up with Autosol by hand to protect finish a bit. It will eventually dull down but cab brought back up. A clear coat is an option but I don't feel the need as I enjoy polishing
     
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    Minimata, Jun 8, 2017
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  17. Minimata

    Minimata Active Member

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    I may put heavier oil in to slow things down a little. Not sure what is in there at the mo.......
     
    Minimata, Jun 8, 2017
    #37
  18. Minimata

    Minimata Active Member

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    Just discovered oil seals need replacing on forks . Anyone know how much oil each leg takes ?

    Just when I had refitted sprayed up fender and new pads etc....

    image.jpg
     
    Minimata, Jul 19, 2017
    #38
  19. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Try cleaning then with a piece of 35mm film negative.
     
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    Murdo, Jul 19, 2017
    #39
  20. Minimata

    Minimata Active Member

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    Cheers Dude, I did try that and it seemed to work then found red oil on deck..... just done it again and seems a lot better. I have ordered some seals but in less of a hurry to fit them now. Thanx
     
    Minimata, Jul 19, 2017
    #40
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