I've finally got round to digging into the 'other' Falco - the one I bought in a knee-jerk reaction of what can only be described as sympathy. I'd known the PO for several years and he's been served a couple of shit sandwiches, on the health and relationship fronts. He can't ride any more (or feels that he can't) due to heart issues and his ex-wife had held his Falco hostage in her garage since 2016. The bike itself had a lot of desirable bits on it (Oz forged ali wheels, Ohlins shock, forks with Ohlins internals (allegedly - haven't verified this yet), Renegade racing airbox and link pipes/cans plus nice bits and pieces (Ohlins steering damper, Aprilia Performance rearsets, RSV Mille swingarm etc. etc.)
However it's absolutely minging filthy, the back of the bike is covered in oil from over-zealous use of a Scottoiler and it's festooned with dodgy electrical gubbins (Sat Nav, phone mount, intercom, aftermarket rear light, decrepit alarm) that basically need ripping off and binning. I'm also not a fan of the Renegade high mount cans, although I'm aware that back in the day they were regarded as the dog's danglies. For me they just get in the way and (on closer inspection) they foul the shark-fin rear hugger on the banana RSV swingarm to the extent that the pipes have burned a large hole in the hugger. I believe that the Renegade kit was only intended for the RSV Mille, but Pete forced it to fit on his Falco without raisng the rear ride height to give working clearance to the hugger. Ho-hum.
So the Renegade exhaust bits have been removed and will be cleaned up, polished and sold on. The same will happen to the Ohlins steering damper (Falcos really don't need one) and the aftermarket smoked rear light lens (another 'essential' mod from BITD that I really don't understand).
Next moves will be to remove the rear wheel and give it a thorough degrease and disinfection, then check out the rear suspension linkages/shock and remove the RSV swingarm for a deep clean and inspection. If all the grease and crud is removed from the bike it will probably shed a couple of kilos...
Inconsequential ramblings of an Old Git
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mangocrazy
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Buckaroo
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
I can take a photo of the Renegade zorst tomorrow, but the rest of the bike is in Stafford and I'm back in Sheffield.
Besides, do you really want pics of a wheel, tyre and swingarm that's caked in grease?
Besides, do you really want pics of a wheel, tyre and swingarm that's caked in grease?
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Rockburner
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KungFooBob
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Re: Inconsequential ramblings of an Old Git
I had a Renegade can on my 400 Bros, that thing was LOUD!
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Buckaroo
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Re: Inconsequential ramblings of an Old Git
Absolutely:before and after shotsmangocrazy wrote: Thu Nov 21, 2024 10:31 pm I can take a photo of the Renegade zorst tomorrow, but the rest of the bike is in Stafford and I'm back in Sheffield.
Besides, do you really want pics of a wheel, tyre and swingarm that's caked in grease?
Besides, I'm a slow reader with little imagination.-
mangocrazy
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Re: Inconsequential ramblings of an Old Git
Shots of the manky arse end of the black Falco will have to wait a week or so, as I won't be back in Stafford until next weekend, when I'll be preoccupied with birthday celebrations. But here are a couple of shots of the 'pre' condition of the Renegade exhaust. First of all, the section of pipe that crosses over from RH side to LH side and sits between the rear wheel and rear cylinder and has been in intimate contact with a plastic (now thoroughly ventilated) hugger:
And a shot of the Renegade 1 into 2 back section comprising link pipes and cans. Hopefully it should scrub up reasonably well with some TLC. They have a reputation for being proper loud, as KFB has alluded to. Also in shot are the passenger footrest hangers that flare out to accommodate the cans that sit directly under the subframe rails.
- DSCF4506.JPG (620.46 KiB) Viewed 1315 times
And a shot of the Renegade 1 into 2 back section comprising link pipes and cans. Hopefully it should scrub up reasonably well with some TLC. They have a reputation for being proper loud, as KFB has alluded to. Also in shot are the passenger footrest hangers that flare out to accommodate the cans that sit directly under the subframe rails.
- DSCF4505.JPG (707.24 KiB) Viewed 1315 times
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
I need to get at the front end of the bike to remove the Ohlins steering damper, and ideally get the front end of the bike up on a steering stem support so I can also remove the front wheel and fork legs. I need to properly inspect the fork legs to see if they need re-chroming (or not, hopefully). The steering damper is buried down by the bottom fork yoke.
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
The triple clamps and forks are identical for Gen 1 Milles and Falcos, so it fits both. And yes, I am intending to sell it.
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
This year is drawing to a close so it's time to get all the bikey things done in the cold, damp, dark days of Dec/Jan/Feb so the bikes are ready to go when we emerge from the tunnel that is winter. First on the list is the LC. The bike is running beautifully now Dave (Muttsnuts) has set up the carburation and now the brakes and suspension are as good as I'm realistically going to get them. The one niggle that persists is a very heavy clutch action. It's even heavier than that on the Falco and as you use the clutch a lot more on a 2T than on a V-twin diesel, it needs sorting.
I'm fully expecting to have to replace the clutch basket, plates and springs, as the bike has done north of 20k miles and is still on all the original clutch hardware. There is also a mod to the gear selector mechanism that I might do, which is supposed to make for smoother gearshifting and makes it easier to find neutral at the lights. So yesterday I drained the coolant and gearbox oil and left them draining overnight. Today the Falco was unceremoniously punted out into the cold and damp while I assembled the Skylift from its component parts and strapped the LC to it. It's quite a small shed and there is scarcely room to swing a cat with both bikes in place. I also tend to get covered in scratches when I try it, so best not to then, yeah?
Draining the LC's fluids is always a bit of a pain. To drain the coolant there are two drain plugs in the water jacket of each cylinder, but they leave a fair bit of coolant still in circuit. The only real way to fully drain the system is to drill and tap a hole in the bottom of the water pump housing. This is pretty much the lowest part of the system. Eagle eyes will spot it in the picture below. Draining the gearbox oil also needs some creativity if the contents aren't to be spread over the shed floor, as the drain plug is directly above the RH expansion chamber/exhaust. Mrs Mango's roll of kitchen foil was pressed into service to direct the oil into the cat's litter tray (only kidding, I have a big tray just for such eventualities).
So what's stopping you from cracking on, I hear you say?
Lunch, that's what.
I'm fully expecting to have to replace the clutch basket, plates and springs, as the bike has done north of 20k miles and is still on all the original clutch hardware. There is also a mod to the gear selector mechanism that I might do, which is supposed to make for smoother gearshifting and makes it easier to find neutral at the lights. So yesterday I drained the coolant and gearbox oil and left them draining overnight. Today the Falco was unceremoniously punted out into the cold and damp while I assembled the Skylift from its component parts and strapped the LC to it. It's quite a small shed and there is scarcely room to swing a cat with both bikes in place. I also tend to get covered in scratches when I try it, so best not to then, yeah?
- DSCF4523.JPG (813.42 KiB) Viewed 1612 times
Draining the LC's fluids is always a bit of a pain. To drain the coolant there are two drain plugs in the water jacket of each cylinder, but they leave a fair bit of coolant still in circuit. The only real way to fully drain the system is to drill and tap a hole in the bottom of the water pump housing. This is pretty much the lowest part of the system. Eagle eyes will spot it in the picture below. Draining the gearbox oil also needs some creativity if the contents aren't to be spread over the shed floor, as the drain plug is directly above the RH expansion chamber/exhaust. Mrs Mango's roll of kitchen foil was pressed into service to direct the oil into the cat's litter tray (only kidding, I have a big tray just for such eventualities).
- DSCF4532.JPG (652.55 KiB) Viewed 1612 times
So what's stopping you from cracking on, I hear you say?
Lunch, that's what.
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
With the howling gales and torrential rain behind us and a period of relatively calm weather in prospect it was time to push the Falco out into the garden, giving me room to work on the LC. I really didn't want to go through the palaver of disconnecting the oil pump cable and the oil supply and feed pipes, so had to find a way of hanging the RH crankcase cover out of the way while still connected. This was achieved with surprisingly little fuss, which is always a bad sign...
The crankcase cover had separated from the crankcases with comparative ease, and even the gasket emerged intact although I'm not sure whether to re-use it or buya new one. A small amount of oil emerged, although not as much as I'd expected, but what oil remained was a nasty sludgy black much like the stuff that energes from forks that have been untouched for decades. I can only assume it's waste friction material from the clutch plates.
The six bolts holding the clutch cover were removed without fuss, followed by the clutch plates, steels and rubber damper rings that Yamaha fit, which left me facing the clutch centre nut. The tab washer was duly flattened (a new one will be fitted on reassembly) and then it was time to break out the clutch holding tool, followed by the electric windy gun and impact socket.
Except that Yamaha, for whatever reason, chose to fit a 29mm AF nut to hold the clutch together and search as I might I couldn't find a 29mm socket. I must have had one to tighten up the clutch centre when I reassembled the engine from a box of bits back in 2020, but I'd be buggered with a splintery gatepost if I could find it now. So the photo below is as far as I could get. I now need to have a good hard think about where I could have mislaid my 29mm socket.
It's probably in France knowing my luck...
The crankcase cover had separated from the crankcases with comparative ease, and even the gasket emerged intact although I'm not sure whether to re-use it or buya new one. A small amount of oil emerged, although not as much as I'd expected, but what oil remained was a nasty sludgy black much like the stuff that energes from forks that have been untouched for decades. I can only assume it's waste friction material from the clutch plates.
The six bolts holding the clutch cover were removed without fuss, followed by the clutch plates, steels and rubber damper rings that Yamaha fit, which left me facing the clutch centre nut. The tab washer was duly flattened (a new one will be fitted on reassembly) and then it was time to break out the clutch holding tool, followed by the electric windy gun and impact socket.
Except that Yamaha, for whatever reason, chose to fit a 29mm AF nut to hold the clutch together and search as I might I couldn't find a 29mm socket. I must have had one to tighten up the clutch centre when I reassembled the engine from a box of bits back in 2020, but I'd be buggered with a splintery gatepost if I could find it now. So the photo below is as far as I could get. I now need to have a good hard think about where I could have mislaid my 29mm socket.
It's probably in France knowing my luck...
- DSCF4535.JPG (852.33 KiB) Viewed 1522 times
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Re: Inconsequential ramblings of an Old Git
I was brought up on RDs and X7s and have a real soft spot for them and made a clutch tool to hold the LC basket still, it looked like a massive pair of scissors 
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
Yes, back in the day I made up a (very sketchy) clutch holding tool from a plain steel plate and an old screwdriver blade. It (just about) worked. Glad to have a proper tool now though...
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
i've owned this LC from new and remember having to wait until August 1980 until getting delivery (I'd put my deposit down in Nov 1979). I really wanted the white/red colour scheme, but at the time you took what you were given, and I got a white/blue one.
I've come to terms with that now...
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
I've always tried to get any updates/repairs to bikes done in the winter time, and preferably this side of Christmas. In my experience, if you leave stuff until the New Year, you suddenly wind up in competition with everyone who has just woken up to the fact that the biking season (nominally) kicks off in less than two months time (and one of those months is 28/29 day February) and who needs parts and work doing. Just like everyone else.
So my Christmas present to me (and dear old Elsie) has been as follows:
New OE Yamaha clutch springs (6 of)
New EBC clutch plates and steels
New OE Yamaha clutch centre lock washer
New Makita clutch basket (made from rufty-tufty 7075-T6 aluminium and hard anodised to boot)
New clutch damper pucks
New Pro-shift selector arm kit (improves gear shift and finding neutral)
Some of the above have already arrived at Mango Towers, the remainder are on their way and should be here before Christmas.
'Tis the season of firing up the shed heater and getting the spanners out...
So my Christmas present to me (and dear old Elsie) has been as follows:
New OE Yamaha clutch springs (6 of)
New EBC clutch plates and steels
New OE Yamaha clutch centre lock washer
New Makita clutch basket (made from rufty-tufty 7075-T6 aluminium and hard anodised to boot)
New clutch damper pucks
New Pro-shift selector arm kit (improves gear shift and finding neutral)
Some of the above have already arrived at Mango Towers, the remainder are on their way and should be here before Christmas.
'Tis the season of firing up the shed heater and getting the spanners out...
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
Earlier today the last package that I'd been waiting for arrived (Special delivery) from Norbo at RD LC Crazy. In addition to the stuff listed above I decided it was false economy to use a 45 year and 20k miles old clutch centre basket and ordered a new OE one from Norbo. It's getting a new clutch outer basket and new plates/steels so it made sense to renew the inner basket. Here's the gang assembled on the kitchen floor:
So first step was to drill out the rivets holding the OE clutch basket and gear plate together. The gear plate will be bolted to the new clutch outer basket with the screws supplied. I drilled all the way through the rivet with a 4mm drill then took the rivet head off with an 8mm drill.
And this is the clutch basket disassembled, showing the component parts (and the remains of the rivets after they'd been punched through). Next step will be to remove all and any traces of swarf, clean everything up and reassemble with the new clutch basket and rubber dampers. And Loctite...
- DSCF4571.JPG (688.52 KiB) Viewed 1062 times
So first step was to drill out the rivets holding the OE clutch basket and gear plate together. The gear plate will be bolted to the new clutch outer basket with the screws supplied. I drilled all the way through the rivet with a 4mm drill then took the rivet head off with an 8mm drill.
- DSCF4566.JPG (888.67 KiB) Viewed 1062 times
And this is the clutch basket disassembled, showing the component parts (and the remains of the rivets after they'd been punched through). Next step will be to remove all and any traces of swarf, clean everything up and reassemble with the new clutch basket and rubber dampers. And Loctite...
- DSCF4570.JPG (665 KiB) Viewed 1062 times
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mangocrazy
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Re: Inconsequential ramblings of an Old Git
A bit more progress made today - the ring gear was removed from the outer clutch basket, doused in brake cleaner to remove as much grease and swarf as possible, then transferred to the kitchen sink for the hot water, detergent and scrubbing treatment. Mrs Mango was otherwise employed in the loft and I seized my opportunity. Timing is everything, I've found...
With an impeccably clean ring (gear) it was time to put the bits back together. Clearances on reassembly were noticeably tighter than on disassembly; the ring gear separated easily from the OE basket and the lttle rubber pucks fell out as soon as the assembly was inverted. When offering up the ring gear to the new basket a fair amount of persuasion with the rubber mallet was required to get them seating snugly, and the new rubber pucks similarly required a bit of force to get them inserted in their new home. This is what it looked like prior to the lid going back on...
The red rubber grease aided the insertion of the pucks and the high strength Loctite would be needed for the next step (refitting the back plate using the supplied flat head allen screws). This is the view from the back of the ring gear with it all bolted together:
And this is the view from the front of the clutch basket:
Before the clutch can be rebuilt onto the bike I need to get the gear selector drum 'starfish' off its shaft and do some reprofiling work. Unfortunately it's never been removed in its 45 year lifespan and had no intention of changing that status. So I'm now waiting for a 2 legged puller of suitable size to arrive by post so I can persuade it to part company with the shaft and embrace its new reality.
Tiny steps, I keep reminding myself...
With an impeccably clean ring (gear) it was time to put the bits back together. Clearances on reassembly were noticeably tighter than on disassembly; the ring gear separated easily from the OE basket and the lttle rubber pucks fell out as soon as the assembly was inverted. When offering up the ring gear to the new basket a fair amount of persuasion with the rubber mallet was required to get them seating snugly, and the new rubber pucks similarly required a bit of force to get them inserted in their new home. This is what it looked like prior to the lid going back on...
- DSCF4584.JPG (646.77 KiB) Viewed 1010 times
The red rubber grease aided the insertion of the pucks and the high strength Loctite would be needed for the next step (refitting the back plate using the supplied flat head allen screws). This is the view from the back of the ring gear with it all bolted together:
- DSCF4588.JPG (561.71 KiB) Viewed 1010 times
And this is the view from the front of the clutch basket:
- DSCF4591.JPG (498.01 KiB) Viewed 1010 times
Before the clutch can be rebuilt onto the bike I need to get the gear selector drum 'starfish' off its shaft and do some reprofiling work. Unfortunately it's never been removed in its 45 year lifespan and had no intention of changing that status. So I'm now waiting for a 2 legged puller of suitable size to arrive by post so I can persuade it to part company with the shaft and embrace its new reality.
Tiny steps, I keep reminding myself...
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Sadlonelygit
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Re: Inconsequential ramblings of an Old Git
Intrigued that the clutch drive gear is not a straight cut gear!
I would have thought that Yamaha would have tried to extract every last hp out of that motor.
I would have thought that Yamaha would have tried to extract every last hp out of that motor.