| Author | Message | ||
     F_skinner |
The S1W rebuild I picked up this bike for a song because it was in very bad shape. (I like to think I saved it from the chopper gods) It had been dropped on both sides. The previous owner did not take care of it and there were a lot of temporary fixes that bothered me. The motor seemed strong but as I started the tear down I found a lot of things wrong. At least rebuilding the bike is keeping out of the streets. So far I have: replaced plug wires, coil, tail light assembly, turn signals, clutch cable, throttle and idle cable, air cleaner, timing cover, clutch cover, header, grips, brake and clutch lever, master cylinder, rear isolators, swing arm and brake pads. I also had the gas tank repainted and the other plastics just need to be cleaned up. I still need to do the front end and may replace the front brake rotor and of course put new tires on her. The pictures are of the body work ready to go back on and I will post more pictures as I get it done. The goal is to have her done for MBV. If it was not for the BadWeb, Al at American Sport Bike, Andy at Appleton HD, Murrae at Santa Fe HD, and the great info on the BadWeb I would not be this for along. The BadWeb really came in handy for the isolator bolts. More Pictures to follow  | ||
| Ratbuell |
Looking good Frank! That tank looks awesome  You headed out east for MBV? If you come thru the DC/Baltimore area, definitely drop me a note. We need to go for a ride together Unfortunately I had to prioritize my vacation time, and this year it's for Homecoming... | ||
| Buell78758 |
Frank, thats awesome your taking the time, trouble, and expense to resurrect an older Buell! A bunch of us from Austin are riding out to MBV (my first), I am riding a 2002 S3T I just got, looking forward to a great time. Will keep my eyes peeled for the sweet SW1. Christian | ||
| F_skinner |
Thanks guys, it is my intention to make it to MBV with the S1W. That is subject to change but that is the plan right now. I need to haul the bike so it will be in the truck, I need to make the 1,800 mile trek to Jville NC and then on to MBV and return. It looks like a good time even though most of it will be spent behind the wheel. I hope to see y'all there. Rat, I will see you at Homecoming. Frank | ||
| Lake_bueller |
Frank...have fun with the S1W rebuild! Mine is a "chopper salvage" bike also. I bought a rolling chassis from a guy in Alabama. Then stole the motor out of a '98 S3T that I bought for a song. Obligator picture:  | ||
| F_skinner |
Lake, I have drooled over that picture many times. It has been inspiration for me. I still have a few odds and ends to get but hopefully will start putting her back together this weekend... Frank | ||
| F_skinner |
New swingarm installed and some of the parts from the old one. The isolator bolts were chewed up pretty bad.   | ||
| Matty |
Looking good Frank! What paint did you use to respray the tank? | ||
| F_skinner |
Matty, I had a painter in Santa Fe NM do the tank. He road a Buell and knew how to do the paint magic to it. There have been a couple of post of the BadWeb on what to use and how to mix it. I think Al at American Sportbike sent me the info which is on another computer. I can send it do you if you want. Frank | ||
| Lake_bueller |
Frank...thanks for the compliment!! She's changed a little from that picture. I crashed at Deal's Gap in 2006. Because I rashed the frame in the process, the whole bike was tore down and rebuilt again. What's really crazy is that I don't have any completed pictures of her "third life". Here's a picture to the motor rebuilt...  She started knocking last summer. I haven't touched her since  Once the weather gets about the teens again, I'll get the workshop going again in the garage. I'm hoping to have her back in shape by May. | ||
| Matty |
Thanks! Please send it along when you get a chance. I guess the Sikkens paint hasn't been available for some time now - someone was able to dig up new numbers for it? I've seen a lot of similar colors, but none have had enough of the pearlescent blue to match the original. | ||
| F_skinner |
Lake, that motor looks great. I have been playing around with the blue/white combo a bit as you can tell from the swingarm. I was going to do it in white but thought that might be too much white. I still need to do the front tubes in blue to balance it a bit but that will wait until next year. Matty, send me your email to f_skinner@yahoo.com and I will send all the info I have. I am not a painter so a lot of it is over my head. | ||
| F_skinner |
Well, I was unable to do much this week due to work but the new rubber is mounted and after fighting the disk mount screws the new front disk is on. My rear stand slipped and I was unable to get the tires mounted but I did make the last piece. I just need to paint the cover white and spot weld the insignia to the timing cover.     | ||
| F_skinner |
Well, this morning started off great, I got the front end back on and was ready to have everything on the front done when the electrical problems I had before resurfaced. I am still trouble shooting the wiring harness and do not want to do anymore until I have it figured out. I hopr I have it done in time for MBV...   I got a new front disk from Al....It looks great... Frank | ||
| Ratbuell |
Frank - you're gonna love that EBC. Looks great, but more importantly, STOPS great! Good luck with the electrical...gremlins suck. | ||
| Lake_bueller |
What are the electrical problems? | ||
| F_skinner |
Brake light, blinkers and dash lights not working. I got the brake light working, it was a short and the dash lights worked until I put the dash back together so that may be a short as well but not important at this point. I did not get around to the blinkers yet, they just do not work at all..... That is tomorrows project. | ||
| Ratbuell |
I always double and triple check the wires in the switch housings. Even when I "know" I didn't pinch anything, 4 times out of 5 I'll find one pinched in there. Sounds like you're on the way, though - the bike looks great! | ||
| F_skinner |
Rat, thanks, I got the left side blinkers to work and the brake light. It was the wiring harness (this time, last time it was a short). I did not get a chance to trace the right side because I already had to much beer and my thought process was getting a little fuzzy. I am hoping to get the rear tire, brake line, fender etc done after work today. Sorry to hear about your doctor imposed riding limitations. Hopefully you will not be out of the "Buell" saddle too long... Frank | ||
| F_skinner |
Well, she is starting to look like a bike again. I found the electrical problems. A shorted wire, repaired, a loose connection in a connector, repaired and a faulty switch, fixed... That took an evening in itself. Due to work I have not had a lot of time to get everything together but it is progressing. I leave for NC and then MBV a week from Saturday so hopefully everything will go together smoothly. Although it never does. I scraped the rank insignia and decided on the VFW shield for the timing cover... Looks like it was made to fit.    | ||
| Sleez |
looking good! | ||
| F_skinner |
I am getting closer but problems crop up at every step. Rear brake would not bleed. I have another one on the way thanks to another BadWebber. The exhaust was a bear to get back together, I do not know if there is a trick to getting the muffler back on the header but if someone has one let me know in case I need to do that again. The petcock did not seal so when I put gas in it out it came. I am going to try some type of sealent when I reinstall. 5 days before I take off for the east coast and MBV and still not on the road yet. I have not given up yet. | ||
| Ratbuell |
You should have an O-ring on the petcock where it goes into the tank, make sure it's not nicked. Original part number 62158-94Y, supersedes to P0301.8. $1.99 retail, I show eight in stock at the moment. If your dealer doesn't have any LMK, I'll toss one in the mail to ya. For the muffler-to-header slipjoint, I cheat and lube it with UltraCopper sealant, then just have to twist it back, and forth, and back, and forth...until it slides far enough on the header to line up. The only downside to this is, if you take it apart again, you have to clean out all the RTV before reassembly. Another trick you can use is to put a large Excalibur-sized screwdriver in the slot on the muffler flange, and spread it open just a bit to aid installation. Always leave the head flanges loose while putting the system together; make sure there are no side-loads on any of the hangars anywhere on the exhaust (bolts should drop in easily, not have to be forced), then start at the heads and torque everything down from there to the rear muffler hangar. It's worked for me so far, no cracks on either the S1W or the S2 Looking good! It's sooo nice to see one being put back together instead of being chopper'd!! | ||
| F_skinner |
Rat, thanks for the info. I do have the O ring but think it just did not seal correctly. I have a spare one (used) and will give it a try. If that does not work I will try something else. I have to have it in the truck by Friday night for an early departure to NC on Saturday. Thanks for the info on the exhaust as well. I finally had to take the headers off the bike to get the muffler on the headers and reassembled it as one unit. I left everything loose until I got it settled and then tightened every up. I was amazed at how easy it went together after that. My rear brake gets here Thursday so Thursday night I will re-attack the rear brake. | ||
| Lake_bueller |
Rear brake would not bleed. I have another one on the way thanks to another BadWebber. How are you trying to bleed the brakes? The rear ones are notoriusly difficult to bleed. I bought one of these "third hand" pumps. I won't bleed them again without it. My guess is that it's not a problem with the brakes. | ||
| F_skinner |
Lake, I have done this many times on many bikes but never on this bike, or any other Buell for that matter. It seemed like I was getting all the air out and the fluid flowing but no pressure. I am interested in that "third hand" pump you mentioned. I imagine it is pretty common and will check J&P cycles tonight. I do not have a lot of time left so if there is a trick to it please let me know. Frank | ||
| F_skinner |
Almost done....    | ||
| Road_thing |
F: If you continue having trouble bleeding the rear brake, try this: Remove rear caliper, leave brake line attached. Hang the caliper above the master cylinder with a hose clamp or a zip-tie or something, so that the caliper is "uphill" all the way from the MC. Put something between the pads in the caliper. Bleed the line. The idea is to give all the air bubbles all the help you can in escaping to the atmosphere. YMMV, but it worked for me. Also, be sure the sealing washers are really sealing. rt | ||
| Mick |
I always fill the brake line from the bottom up, using a srynge and some hose on the caliper nipple. forces the air up thru the line and up out of the reseviour, works for me. | ||
| F_skinner |
RT, thanks, I will give that a try... Frank |
