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Topics - Ewan 500 K1
16
« on: August 23, 2013, 09:14:46 PM »
Bit of a funny one when setting up my dual discs. The caliper arm for the additional disc on the right hand (speedo drive Side) was perfectly aligned with the disc without any need to mess around with shims or files contrary to all expectation (photo one) (later ... of course this is wrong , as identified by oddjob, while it's true that caliper arm shoud be parallel in vertical and horizontal planes with the disc, it should not be flush with the disc.. it should be offset a couple of mm to the outside of the disc), but the original set up on the left hand side is misaligned (second photo) and had to be brought into line by putting some washers in between the caliper arm and the fork.... see photos 3 & 4 and close ups in next post. Anyone got any idea whats gone wrong ? . I have changed the wheel from the original.. maybe its that , see two posts down
17
« on: August 23, 2013, 02:30:31 AM »
Procedure captured in photos below:
Photo 1: Bearing seat in top of headstock
Photo 2: Nifty wee bearing seat removal tool
Photo 3: Tool in place on top of headstock
Photo 4: Drift inserted from bottom of headstock
Photo 5: Couple of whacks on the drift with a rubber mallet and the bearing seat is out
Repeat at the other end to get the bottom seat out ... bit more tricky as this seat's diameter is about the same as the headstock inner diameter and may be flush into the shoulder, so next to nothing for the tool to grab onto. Expand the tool as much as possible and the first couple of thumps on the drift should move it enough through friction to get a gap between the seat and the shoulder it sits in for the tool to get a better grab on it
18
« on: August 21, 2013, 01:36:15 AM »
Hi,
Just getting the frame ready for powder coating. Does anyone know if I need to remove the bronze bushes from inside the swing arm pivot tube ? They are in fine condition and I'd rather not have to buy new ones if I dont need to. Same with the taper roller bearings in the steering stem, do I need to take the bearing seats out ? Last, I guess that the rear shock bushings on the swing arm will definetey need removed as they are part rubber ? I'd be interested in any other hints and tips for prepping for powder coating anyone has too
cheers
19
« on: August 07, 2013, 12:48:35 AM »
Hi, anyone got a 500 K3 or 550 K3 that could do me a a wee favour. I bought a pair of second hand rearsets off ebay a while ago hoping to use them on my 500K1 ... but the rear brake spindle is too big in diameter to fit in the hole in the frame ... ie the rearset part that replaces part 15 in the attached diagram is too fat in diameter. Its not miles out , maybe a millimetre at most. Would really appreiate if somone with a K3 could measure the diameter of part 15 in the ddiagram (part number 46515-404-670) and let me know . The spindle part number changes from the K1/K2 to the K3 , so wonddering if the rearset would fit a K3
20
« on: July 31, 2013, 06:50:25 AM »
Hi , anyone got a spare battery box for a 500 or 550 four ?
21
« on: July 24, 2013, 10:54:27 PM »
Hi Folks, just got my engine back togeather today and its now ready to go back in the fram so that I can start to do a full new wiring loom for the cafe racer. This will be my first attempt at doing a full rewires, anyone got any idea what size / spec of wires I should be using for the various circuits ?
22
« on: July 19, 2013, 04:00:30 PM »
Dave Silver is out of .5 oversize piston rings, Anyone know of an alternative suplplier
23
« on: January 14, 2013, 08:51:00 AM »
what a pain in the arse ... went to take the rocker cover off for polishing and found that two of the four central bolts have sheared flush. I'm loathe to use an easy out as I've had them snap off before. Anyone tried the sealey VS7233 stud extractor .... http://www.pvrdirect.co.uk/productinfo.aspx?catref=VS7233 . .... in particular are the pins liable to snapping in the same way as easy outs ?
24
« on: October 27, 2012, 11:50:35 AM »
Hi, I'm just about ready to start making up a new wiring loom for me 500/4. The old loom is shot to bits and I'm doing a cafe job, so a standard loom isnt what I'm looking for. I want to build a custom loom and I want to use best quality wiring and connectors. Anyone got advice on a supplier?
25
« on: August 06, 2012, 02:06:44 AM »
......due to the need to have a stop lamp, rear light and a registration plate....not too mention indicators. I'm having a real struggle coming up with something for the back lights set up that is legal but doesnt look like a beurocratic minger........ just woke up at 2am and had to go out to the shed and do a mock up of a potential solution using carboard and red insulationg tape. In the photo red circle = reflector, red strip = rear light / stop light using a dual intensity flexible LED strip. That's about as good as I can think of right now, hoping its UK legal...... Anyone else had a mindwarp with this ?
26
« on: August 04, 2012, 10:45:06 PM »
27
« on: March 03, 2012, 05:22:35 PM »
I have bit left over from front & rear wheel builds on a 500 four . .. a steel washer/spacer. Cant see it in the parts diagrams, but am sure it came from either the front or back axle... slightly complicated by the fact that the bike is a mongrel of 500/550/750 parts. Photos of this bit below.. anyone know what it is / where it should go
28
« on: March 03, 2012, 12:11:37 PM »
here's a bugger. Polished up my rear hub and respoked it with a new rim. Then, dug out a better looking brake plate, polished it up, went to fit it to the hub and ... it disnae flippin fit. It does look a bit different (see first photo) and is stamped 398 . Anyone know what models this fits, is it off a 550 or 750 four ? ... anyone needing one of these. Me ? ... I'll need to polish up the original brake plate (photo 2)
29
« on: December 30, 2011, 04:48:39 PM »
Time to get the 500 four back on the road after a break of three years, this time this time to finish the cafe racer job that was started about 17 years ago
Done : Full Engine rebuild about 3000 miles ago.
To do:
K&N Air Filters (done)
Straight through pipes (done)
Rejet with 110 mains/ clean / syncronise carbs (done)
Rebuild both wheels with new rims & spokes(done)
Dual Disc front brake conversion (done)
Drill front sprocket cover
Remodel Front Mudguard (done)
Drill brake discs (done)
Detag & shorten Frame (done)
Replace stock speedo/ rev counter (done)
Ace Bars (done)
Custom Tarozzi Rear Sets on rear foot peg hangers (done)
Relocate Battery (done)
Rewire from front to back and everywhere in between (done)
New Headlight (done)
New idicators (done)
New speedo (done)
New rear lights set up
New longer rear shocks (done)
New front mudguard (done)
Polish alloy (done)
Braided Stainless Fuel & Brake Hoses (done)
Stainless Bolts througout (done)
Refurbish Front Forks (done)
New Rear Shock Swing Arm Bushes (done)
New Plugs
Powder Coat the frame
Investigate effect of longer rear shocks on bike geometry and make front end adjustments if necessary (nearly done)
Fit Steering Damper (done)
Fit grease nipples to front break caliper arm pivot points (done)
Tune carbs
Get MOT, tax and insurance
30
« on: December 21, 2011, 10:11:42 AM »
Inherited a 500 four when my young bro died in 1997 aged 28. Benn tinkering with it ever since. Full engine rebuild about 3000 miles ago, now doing cafe racer conversion ... twin discs, wheel rebuild, frame detagging, new headlight, custom speedo, dumping the rev counter + rear mudguard +rear lght unit + indicators + side panels and whatever else I can, allen bolts on engine and carbs, K&N's, straight throughs, rejetted carbs, rear sets, ace bars, dyna ignition, stainless braided hoses, new shocks, polishing ally parts, realoating battery and electrics. Never done much of this before, so this forum is a real godsend.
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