Building a café racer called „Uschi“

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Re: Building a café racer called „Uschi“

#16

Post by Neil »

I like the beer caps, adds character.
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Re: Building a café racer called „Uschi“

#17

Post by Roady »

Love the old Beemers and the caps do give it that German flair.
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Re: Building a café racer called „Uschi“

#18

Post by LastMohawk »

Thanks,

my wife said, i spend more time with the old wing thang with her.... :roll:
but i'm sure when finishing the bike, she will love to ride through our moutains :crosso and take a rest in a bikers cafe for a cup of cafe an a strawberry cake...
"Sometimes it takes more than luck to keep the wheels spinning just right."

77 GL1000 "Uschi"
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Re: Building a café racer called „Uschi“

#19

Post by sunnbobb »

Nice work!
I found the end of the internet

---- Bradshaw Bikes custom polishing for your wing. Visit us on facebook!

1978 Learning Experience
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Re: Building a café racer called „Uschi“

#20

Post by LastMohawk »

Hello there,

yes, Uschi will still alive dancr .
In 2013 we had to drive the beemer and no time for the wing. The in 2014 I was not able to drive, had enough time for Uschi. Cause we are still fighting against my wife's kidney Tumor. crying1

She isn't able to drive a bike, so i had to stay at home and spend my sparetime in my workshop and she is looking what i will do. there are two Projects... of course Uschi will become a Caferacer and a russian Bike with a sidecar called Ural. We hope that may wife will be able to sit in the sidecar and enjoy the roads arround. We will see....

Now i have time to sort the Pictures she took from my work and write the Story about the building.

The first Thing war renew the starter.
Here are some Pics from cleaning and renew the starter. Sorry, I did not have a picture from the original state.
Here you can see the whole parts of the starter in order of their Locations.
Anlasse_Zerlegt.JPG
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It seems, Mr. Honda loves washers lolol

I cleaned the mechanical parts with mineral spirits and the electrical parts with alcohol, sanded the housings and colored them.
Here are the electrical parts of the starter
Anlasse_elTeil.JPG
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I sanded off the collector and had ground the brushes. Make sure that no copper dust between the collector fields, otherwise you risk an electrical short circuit.
And here the mechanical parts:
Anlasse_mechTeil.JPG
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The gearwheels should be carefully lubricated with graphite grease
And here is the assembled starter. Ready for installation.
Anlasse_elAnschluss.JPG
Anlasse_elAnschluss.JPG (41.79 KiB) Viewed 425 times
next i will repair the water pump... paint the engine... building the bowden cable... and the wiring ...

hope you will enjoy my Little stories

greetings
Harald
"Sometimes it takes more than luck to keep the wheels spinning just right."

77 GL1000 "Uschi"
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Re: Building a café racer called „Uschi“

#21

Post by ericheath »

We love picture book stories. Nice work!
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77 WING, 1200 engine with 77 heads, cams, gl1100 foot pegs, Magna V65 front end, 764A carbs, [-gone Suzuki M109 monoshock--, replaced with gl1100 shocks] gl 1200 swing arm, gl1500 final drive, wheel and rear brakes Valkyrie seat, Meanstreak tank, Sportster pipes, Power Arc ignition off crank.
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Re: Building a café racer called „Uschi“

#22

Post by Casper »

Very nice work, plus the pictures are just great!, thanks. All the best with your wife's Kidney Tumor, my wife and I are battling her recent Uterine Cancer diagnosis.
1976 LTD, Being Returned to Stock
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Re: Building a café racer called „Uschi“

#23

Post by CYBORG »

Looks good Harald. And my best wishes for your wife's recovery
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Re: Building a café racer called „Uschi“

#24

Post by theburgundian »

Whao, what a lot of work!
I'm impressed, as I am as I look all of the restoration projects here!

Could you please mention the website where you found your hyundai timing belt tensioners please? I'm short of money to restore my Wing...
Always look on the bright side of life buddy
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Re: Building a café racer called „Uschi“

#25

Post by LastMohawk »

Thanks to all for the good wishes to my wife.... action1
theburgundian wrote:Whao, what a lot of work!
....
Could you please mention the website where you found your hyundai timing belt tensioners please? I'm short of money to restore my Wing...
look here from reseller in Berlin http://www.ebay.de/itm/Original-SKF-Uml ... 566df71d38 But he will send it i the whole EU

The timing belt tensioners are for Hyundai Coupe, Elantra, Lantra, Tuscon, i30 till 05/2006
there are several Partnumbers:
SKF: VKM 85153
HYUNDAI: 24810-23400,
HYUNDAI: 24810-23011
HYUNDAI: 24810-23500,
HYUNDAI: 24810-23050

hope you will find one

Greetings
Harald
"Sometimes it takes more than luck to keep the wheels spinning just right."

77 GL1000 "Uschi"
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Re: Building a café racer called „Uschi“

#26

Post by theburgundian »

I'm sorry, I didn't see about your wife's health. I wish her to get better, maybe the ural sidecar (which is a good motorbike) will help her to raise moral and health!
Always look on the bright side of life buddy
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Re: Building a café racer called „Uschi“

#27

Post by LastMohawk »

Thanks to France for your words...

I will Show you the finished Carbs with the special crown caps... 2 Caps of beer from Cologne, one Cap from my Birthplace in the Blackwood Forrest and one cap for my favorite drink Coke anim-cheers1 the last two caps aren't on the Picture but meanwhile mounted.

i had about one week to renew thiese carbs and make them shiny.
Vergaser_1.jpg
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Vergaser_2.jpg
Vergaser_2.jpg (71.93 KiB) Viewed 409 times
the pictures were taken last summer.... now it's snowy outside :-)

Greetings
Harald
"Sometimes it takes more than luck to keep the wheels spinning just right."

77 GL1000 "Uschi"
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Re: Building a café racer called „Uschi“

#28

Post by Neil »

Nicely done Harald. Prayers for your wife.
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Re: Building a café racer called „Uschi“

#29

Post by LastMohawk »

Now the next step:
Rebuild the water pump - Part 1 -

First I read these Tutorials here at the Shop Talk:
Water Pump Leak, Why& How by Octane - There are only 2 things it can leak. http://www.ngwclub.com/forum/viewtopic.php?t=6863
Water Pump Rebuild (unsuccessful) by Octane - Lots of details, good pics, but, no-go. http://www.ngwclub.com/forum/viewtopic.php?t=3230
Water Pump Job by Roady - For those who know how to get to it. http://www.ngwclub.com/forum/viewtopic. ... 44#p138444

And here is the repair kit wingman told me in post number #6.
This repair kit is for the water pump with the impeller made of Bakelite®. There are repair kits for the metallic impellers too.
Repsatz.jpg
Repsatz.jpg (70.7 KiB) Viewed 397 times
This Picture is taken from the eBay-site

I could move the wheel of the pump nearly 5mm from left to right and up and down…
WP_Ausbau_Rad.JPG
WP_Ausbau_Rad.JPG (72.68 KiB) Viewed 397 times
The pump is mounted with 3 screws on the back, so you have to disassemble the lower front cover.
WP_Ausbau_Welle.JPG
WP_Ausbau_Welle.JPG (36.11 KiB) Viewed 397 times
Looks like there is no oil on earth…. only water and rust  :drunk
But the shaft is straight and does not corrode and the impeller is not broken. Good conditions for the repair kit.

Here are the disassembled parts and the technical drawing of the pump.
WP_Ausbau_Zeichnung.JPG
WP_Ausbau_Zeichnung.JPG (36.96 KiB) Viewed 397 times
the shaft is secured with a locking ring. The shaft can be removed by fixing the housing between 2 end wrench and a hearty hammer. Be careful with the Bakelite impeller, it will damage very easy. And Honda will sell it for good money…. Better to use this money later at the gas station. :crosso
Now clean the Impeller, the shaft and remove the old bearings from the housing.

Now it’s time to rebuild the water pump.
These parts are included the repair kit.
WP_Einbau_1_Satz_komplett.JPG
WP_Einbau_1_Satz_komplett.JPG (51.13 KiB) Viewed 397 times
next see Part 2 ......

Greetings
Harald
"Sometimes it takes more than luck to keep the wheels spinning just right."

77 GL1000 "Uschi"
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Re: Building a café racer called „Uschi“

#30

Post by LastMohawk »

Rebuild the water pump - Part 2 -

First we had to install the bearing behind the mechanical seal. The outer diameter of the bearing fits exact my 19mm socket wrench. This bearing has to be mounted pushing the outer bearing shell.
WP_Einbau_2a_Lager.JPG
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WP_Einbau_3_Lager.JPG
WP_Einbau_3_Lager.JPG (42.68 KiB) Viewed 395 times
Next mount the right bearing in the same way. Be sure you put the small alloy small tube (in the pic this tube si in top of the housing) between the two bearings. This tube will correct the distance between the bearings.
WP_Einbau_4_Lager.JPG
WP_Einbau_4_Lager.JPG (44.76 KiB) Viewed 395 times
Next step is mounting the mechanical seal. There are 3 parts of it. First mount the ceramic Part (white) on the back of the impeller. Be careful the impeller is like a “Diva” very nervous and will break easy.
WP_Einbau_4_Dichtung.JPG
WP_Einbau_4_Dichtung.JPG (38.08 KiB) Viewed 395 times
Next push the metallic part in the housing of the pump.
WP_Einbau_1_Dichtung.JPG
WP_Einbau_1_Dichtung.JPG (52.37 KiB) Viewed 395 times
Please use Oil like Oil for weapons to mount the seals and the bearings. It’s easier and save money.

see Part 3...

Greetings
Harald
"Sometimes it takes more than luck to keep the wheels spinning just right."

77 GL1000 "Uschi"
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