62 FL Chop Rebuild 12
Still putting parts together....
Starting working on the clutch and front brake parts....
The clutch lever is already sized for 1" handlebars, so that's a bolt on...
But this master cylinder is for 7/8" handlebars, so needed to be drilled out...
By splitting a 1/8" washer in half, and bolting it in as a spacer, the up and down dimension is
now at 1", and I'll use the 1" "unibit" to take the sides out to 1"
Took my time and it came out quite nicely, cleaned it up with a hand file....
Bolted it on the handlebar, right side, and with the forks resting at full left,
the reservoir is perfect for filling/checking...
Bolted the clutch lever on also, will shorten the levers to match the short hand grips....
Had a couple hours so ran up to the shop....
My buddy had a small cylinder hone that fit....
So, honed 'er nice and smooth and stuck the parts in....
And put 'er back on the bike....
Oh, I think I'm in love....
Gonna keep the bars here....
Do notice though, that with an allen and a box end, I can rotate those foot pegs up higher....
More Later....
OK, Later.... thinking on how I want to wire it....
One switch, a DPDT, neutral is off, rear is rear light only, tail is on to load the gen set
and have it productive, when I switch it forward and turn on the headlights.
This will be fun !!
Had a little time today, so pulled the front brake apart,
as the caliper bracket had never been painted....
I could have smoothed out those rough spots a bit....
but the caliper covers it all up, it will never be seen on the bike....
The rotor carrier also needed paint, it cleaned up pretty nicely....
I'm wondering if I need to install the five studs like the oem HD brakes use,
It looks like over kill to me, but I suppose that if these five bolts were to loosen
and fall off, the studs would keep the brake from spinning, at least...
I measured the studs on this rear brake drum, they average 0.455", a really odd size...
The closest fractional size is 29/64", or 0.453", which is pretty close...
I also checked metric , but it is about in the middle between 11 mm and 12 mm,
so I do not know where HD came up with this size...
Decided not to do the studs, reassembled the brake setup with the freshly
painted rotor carrier....
Used blue locktite on these nuts....
Lookin' good....
Attached it to the wheel and used red locktite on the wheel bolts....
Back together with the freshly painted caliper bracket...
Again, lookin' good....
Bought 104 links of new O-ring chain, but with the axle all the way forward,
it looks like 100 links is all I will need.
One problem, the chain is running too close to the back side
of the clutch assembly...
But as I have ordered parts to replace this wear pad on the back of the clutch hub,
that will move the clutch basket assembly away from the chain,
it should be enough to get adequate running clearance.
More Later
