/ Register

  1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

Project Joker's Angry Fizzer 400

Discussion in 'Other Projects - Other Bikes (non 250's)' started by Joker, Nov 4, 2016.

Page 4 of 14
  1. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

    Messages:
    3,233
    Likes Received:
    1,423
    Trophy Points:
    918
    Joined:
    Oct 1, 2013
    Gender:
    Male
    Location:
    Narrabeen, NSW Australia
    My Bike:
    Yamaha FZR250 3LN1
    ruckusman, Dec 8, 2016
    #61
  2. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

    Messages:
    3,233
    Likes Received:
    1,423
    Trophy Points:
    918
    Joined:
    Oct 1, 2013
    Gender:
    Male
    Location:
    Narrabeen, NSW Australia
    My Bike:
    Yamaha FZR250 3LN1
    I ended up making my own - way too much fuss and I cannot recall my final solution - I think it involved a drilled steel rivet nut with a stainless sleeve over the cable and held into the rivet nut with a stainless grub screw - it works, but took me ages to arrive at that solution

    Now I suspect you might be able to source servo rod control ends from a hobby store that will go straight on much more easily
     
    ruckusman, Dec 8, 2016
    #62
  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

    Messages:
    4,313
    Likes Received:
    2,383
    Trophy Points:
    898
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide, South Australia
    My Bike:
    Yamaha's , 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G, 1976 IT400C 510
    I normally make my own cable's and end's
    Some of the bigger lead bicycle end's can be filed down, drilled and soldered to the cable
     
    • Like Like x 1
    my67xr, Dec 8, 2016
    #63
  4. Joker

    Joker See "about me" for contact details. Contributing Member

    Messages:
    2,737
    Likes Received:
    1,399
    Trophy Points:
    798
    Joined:
    Feb 2, 2014
    Gender:
    Male
    Location:
    Switzerland
    My Bike:
    SV1000SK3
    Well it sounds like you guys are very industrious which is a great quality. The first time around I spent a couple of days looking in the end it was time wasted because not only could I not find everything I needed, I couldn't even find what you're talking about to file it down or drill it myself. Sweet relief was watching the $20 go to venhill knowing I didn't have to go through all that again, and hence why I did it again this time. Each to their own I suppose, for a $150 part I might be a bit more pedantic but for $20 - big winner in my books to save me the frustration I know I would endure if I attempted any of that myself!
     
    Joker, Dec 8, 2016
    #64
  5. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

    Messages:
    4,313
    Likes Received:
    2,383
    Trophy Points:
    898
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide, South Australia
    My Bike:
    Yamaha's , 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G, 1976 IT400C 510
    I was talking about one of the bar nipple's on the end of the cable.
    Heat it up with a butane or propane torch and then carefully pull the end off the cable.
    Drill it to suit the new cable if needed, and file it to the size required.
    Fit it to the end of the new cable, apply some Baker's soldering fluid and then solder it on

    [​IMG]

    Otherwise you can use a piece of bronze rod and drill it to suit, fit it to the cable, then centre punch the end's to hold the cable in

    [​IMG]
     
    • Like Like x 1
    Last edited: Dec 8, 2016
    my67xr, Dec 8, 2016
    #65
  6. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

    Messages:
    4,292
    Likes Received:
    2,508
    Trophy Points:
    918
    Joined:
    Oct 6, 2016
    Gender:
    Male
    Location:
    Albury 2641
    My Bike:
    1987 Yamaha SRX250, Honda 1974 SL125 K1, 2022 Triumph Tiger Sport 660
    Old School skills.. :) good to see they are still in use.
     
    • Like Like x 1
    Andych, Dec 8, 2016
    #66
  7. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

    Messages:
    3,233
    Likes Received:
    1,423
    Trophy Points:
    918
    Joined:
    Oct 1, 2013
    Gender:
    Male
    Location:
    Narrabeen, NSW Australia
    My Bike:
    Yamaha FZR250 3LN1
    The guiding factor for me was - bike off the road meant time on the bus at the time, actually now that I've gone through the process I'd do it again for difficult to access replacement cables.

    Here are the rivet nuts

    [​IMG]
    Drill accurately down through centre, chuck in drill to spin off excess length and flange with an angle grinder using a flap disc and the sheath over the cable made the fixation with the grub screw very secure.

    The beauty is for any that have these replacements done, I can re-use the ends in the future if necessary.
     
    ruckusman, Dec 8, 2016
    #67
  8. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

    Messages:
    3,233
    Likes Received:
    1,423
    Trophy Points:
    918
    Joined:
    Oct 1, 2013
    Gender:
    Male
    Location:
    Narrabeen, NSW Australia
    My Bike:
    Yamaha FZR250 3LN1
    This is the type of thing I was mentioning which would be really quick and easy, servo control rod/cable connectors, pre-drilled just need grub screws

    [​IMG]
     
    ruckusman, Dec 8, 2016
    #68
  9. Joker

    Joker See "about me" for contact details. Contributing Member

    Messages:
    2,737
    Likes Received:
    1,399
    Trophy Points:
    798
    Joined:
    Feb 2, 2014
    Gender:
    Male
    Location:
    Switzerland
    My Bike:
    SV1000SK3
    Oh I understand perfectly what you're saying and power to you for all these clever improvisations :)
     
    Joker, Dec 8, 2016
    #69
  10. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

    Messages:
    4,292
    Likes Received:
    2,508
    Trophy Points:
    918
    Joined:
    Oct 6, 2016
    Gender:
    Male
    Location:
    Albury 2641
    My Bike:
    1987 Yamaha SRX250, Honda 1974 SL125 K1, 2022 Triumph Tiger Sport 660
    That was how you used to buy brake and gear cables for pushies back in the day... lol
    Cable outer was generally OK so you would replace the inner and end up with frayed ends...lol
    Plus if you didn't manage to do them up tight enough... the cable would slip... mostly on the gears.
     
    • Like Like x 1
    Andych, Dec 8, 2016
    #70
  11. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

    Messages:
    3,233
    Likes Received:
    1,423
    Trophy Points:
    918
    Joined:
    Oct 1, 2013
    Gender:
    Male
    Location:
    Narrabeen, NSW Australia
    My Bike:
    Yamaha FZR250 3LN1
    For future reference for anyone with a broken EXUP cable- keywords EXUP cable repair replacement parts

    What size are the EXUP cable ends?

    These would need a hole down the centre - I suspect they're too big on the diameter for the exup - search for threaded round on ebay
    http://www.ebay.com.au/itm/M4x10mmx...nd-Coupling-Connector-Nuts-20pcs/351787213253

    6mm diameter - 8mm long - search for threaded round on ebay - these may also work for clutch cable repair
    http://www.ebay.com.au/itm/10pcs-M3...d-Bar-Stud-Round-Connector-Nuts-/252441600228

    4mm diameter - 6mm long - search for linkage stopper on ebay - there are loads, this is the sort of thing available at RC hobby stores
    http://www.ebay.com.au/itm/282e-10x...06-hard-brass-suit-for-RC-Model-/201039729987

    I'm pondering getting the right ends and cable prepped ready for install for emergency repair. I remember 2kms struggling home with the exup cable broken, I wouldn't have made it had it been further
     
    ruckusman, Dec 10, 2016
    #71
  12. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

    Messages:
    3,233
    Likes Received:
    1,423
    Trophy Points:
    918
    Joined:
    Oct 1, 2013
    Gender:
    Male
    Location:
    Narrabeen, NSW Australia
    My Bike:
    Yamaha FZR250 3LN1
    • Like Like x 1
    ruckusman, Dec 10, 2016
    #72
  13. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

    Messages:
    4,737
    Likes Received:
    2,883
    Trophy Points:
    943
    Joined:
    Mar 18, 2014
    Location:
    Sydney NSW
    My Bike:
    FZR250R 3LN6
    • Like Like x 1
    Linkin, Dec 10, 2016
    #73
  14. Joker

    Joker See "about me" for contact details. Contributing Member

    Messages:
    2,737
    Likes Received:
    1,399
    Trophy Points:
    798
    Joined:
    Feb 2, 2014
    Gender:
    Male
    Location:
    Switzerland
    My Bike:
    SV1000SK3
    Joker, Dec 11, 2016
    #74
  15. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

    Messages:
    3,233
    Likes Received:
    1,423
    Trophy Points:
    918
    Joined:
    Oct 1, 2013
    Gender:
    Male
    Location:
    Narrabeen, NSW Australia
    My Bike:
    Yamaha FZR250 3LN1
    they actually sell just the nipples also, which is a bonus
     
    • Like Like x 1
    ruckusman, Dec 11, 2016
    #75
  16. Joker

    Joker See "about me" for contact details. Contributing Member

    Messages:
    2,737
    Likes Received:
    1,399
    Trophy Points:
    798
    Joined:
    Feb 2, 2014
    Gender:
    Male
    Location:
    Switzerland
    My Bike:
    SV1000SK3
    The head is back, machined nicely and with the new threads done. He tested them up to 10nM so I'm confident the issue will go away. The valve cover gasket came from Israel and sooner than the gasket kit from the UK but I hope to have that this week and she'll go back together. I'll drop the sump off and give it a bit of a clean because the kit has everything in it so I may as well ensure all the goop is completely gone.

    15591547_10157901853755716_6239450312606937093_o.jpg

    And by the way... I decided on a colour scheme...

    4017front.jpeg

    4017side.jpeg
     
    • Like Like x 3
    Joker, Dec 18, 2016
    #76
  17. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

    Messages:
    4,313
    Likes Received:
    2,383
    Trophy Points:
    898
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide, South Australia
    My Bike:
    Yamaha's , 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G, 1976 IT400C 510
    The price for the kit is pretty good too, starting at $239
     
    my67xr, Dec 18, 2016
    #77
  18. Joker

    Joker See "about me" for contact details. Contributing Member

    Messages:
    2,737
    Likes Received:
    1,399
    Trophy Points:
    798
    Joined:
    Feb 2, 2014
    Gender:
    Male
    Location:
    Switzerland
    My Bike:
    SV1000SK3
    Yes specifically they said (I emailed them) $239 plus $27 shipping, plus it comes with test bits.

    4015,-instructions.jpg
     
    • Like Like x 2
    Joker, Dec 18, 2016
    #78
  19. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

    Messages:
    4,313
    Likes Received:
    2,383
    Trophy Points:
    898
    Joined:
    Jun 18, 2016
    Gender:
    Male
    Occupation:
    Panel Beater, Spray Painter, Custom Fabricator
    Location:
    Adelaide, South Australia
    My Bike:
    Yamaha's , 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G, 1976 IT400C 510
    So you're having it resprayed too?
    Straight black or Blue/Black pearl ?
     
    my67xr, Dec 18, 2016
    #79
  20. Joker

    Joker See "about me" for contact details. Contributing Member

    Messages:
    2,737
    Likes Received:
    1,399
    Trophy Points:
    798
    Joined:
    Feb 2, 2014
    Gender:
    Male
    Location:
    Switzerland
    My Bike:
    SV1000SK3
    I gotta get another quote but I think it will be straight black gloss.
     
    • Like Like x 1
    Joker, Dec 18, 2016
    #80
Page 4 of 14

Share This Page