My Buddie's POW/MIA K-3, and How to do fork seals, duel disc breaks, and engine rebuild.

[TOOLS1]

This is what we started with. I think it was the original motard.


Started dis assembly.






Removed the triple tree, and found an Allballz tapered roller bearing conversion.


This is how the races are supposed to look when installed. Top one sticks up about 1/16 inch, and bottom goes in about 1/16 inch.


Here is a comparison of the 750, and 500/550 speedometer drives. You need the 500/550 drive, for duel discs, but later I might show, you how to use the 750 one. If your nice


Here is how the 500/550 speedometer drive installs. Be sure to use loctite on those nuts. Also make sure to have them on the right side.

More to come.
TOOLS

[Piute]

  Bike didn't come stock with duel disc ? Bottle jack mmm needed that thought today,will use tomarrow,lil flo jack gets in the way,Bolts on right side speedo gear on right also ? for that bike.

[TOOLS1]

No that bike only had one disc. He had added one a few years ago, but, for some reason he could not get them to line up right. Had shims, and spacers between the brackets, and the forks. Breaks would not release. Big mess. Yep the speedo drive goes on the right. that's why, you need the 500/550 speedo drive. The 750 is too big to fit into the disc.
TOOLS

[Piute]

  When I put my wheel back on ,looking from the front the left side (leg)was over to close to disc 1/8" ,by putting in the axial the other way, " Mr.CLYMER only shows wire wheel "put it were needed for now(distance the same),haven't check with calipers on,( waiting on kit).

[shinyribs]

I keep seeing bikes with that aluminum fork brace.Was that a factory deal or something people added later.Pops' trike has on,but figured it was because of the  10"longer forks.Whats up?Btw,i think we have just witnessed a very rare Tools sighting...

[TOOLS1]

LOL. No that was a Toolbuddy, or Gerald sighting. That aluminum thing is a fork brace. They were popular back in the day. When the forks are extended they start to flex. The brace made them a little stiffer. They are kind of hard to come by today. They are also coll when, you use gators on an extended front end. You put it on the forks above the gators. Very cool old school chopper look.
TOOLS

[shinyribs]

I dig 'em.Pops has one on his old trike,think i'm gonna steal it.You know...polish it up real nice for him???

[TOOLS1]

Lets see. Where did I leave off? Oh yea the speedometer drive. Now lets replace the seals on the forks, and get them ready.


First drain the fork oil/ATF by removing this little bolt, and pumping the fork. You do not have to pump hard. Just move it an inch, or, so several times. Until the oil stops spurting out. Then remove the 6mm allen head bolt at the bottom of the fork leg. An impact really helps.


Now slide the tube out of the slider, and this is what, you should have. Remove the snap-ring. To remove the seal, heat up the slider around the top where the seal is. I use a heat gun, but hot water, or a torch does the job also. Then just pry it out with a sturdy screw driver. The seal should go flying across the room, so be careful.


Now clean the slider, and put a thin layer of silicone sealer on the slider where the seal goes in.


Now start the seal in. Then shove it down the rest of the way using a large socket. It's OK if, you go too deep. It does not have to be against the snap-ring. Now reassemble the fork by reversing the order. And put 5.5oz ATF in each fork.
TOOLS

[TOOLS1]

Now that, you know how to install fork seals. Let's get back to the build.
All the aluminum parts have been sanded, and polished to perfection.
 

 

 

I have started to reinstall everything. The left break caliper bracket goes on first. Then the fender just like the factory did it. However on the right side. Remove the rubber grommets from the fender bracket. then install the caliper bracket over the fender bracket. Install a washer under the bottom bolt as a spacer. This will keep the caliper bracket lined up.

 

Getting close now.

TOOLS

[shinyribs]

Oh man those forks look good!!!!I wanna do mine but don't know how hard it would be.Any tips?

[TOOLS1]

Get a high speed polisher/buffer, and a good buffing wheel. I got my buffing supplies from Tar Heel supplies in North Carolina.
Sand with a DA sander down to 220 grit. Then buff. Do not use a lot of pressure, and do not over load the wheel with compound. After buffing with machine. Buff by hand with old thermal underwear material, and corn starch.
TOOLS

[shinyribs]

underwear and cornstarch...sorry i asked      just kidding   thanks boss!

[TOOLS1]

Here's the link to Tarheel http://www.tarheelparts.com/
TOOLS

[ksharp]

looks good man im loving this build right now

[TOOLS1]

Here is something I forgot. On the right fork leg. The locknut on the adjuster needs to go on the inside. There is a little difference between the sliders where the break sdjuster goes.
 

Now I have to reconnect all this.
 

And fix this.
 

 
As, you can see in the last picture. I am ready

If the lights at the rear are not working. Just run extra wires to the front, and hook on, or vice versa.
 
TOOLS

[TOOLS1]

Here is how the wiring looks now. That was a lot of wires to hide.
 

 

Here is the bike all put back together. Now to have the Braided Stainless Steel lines made up.
 
TOOLS

[shinyribs]

That was fast!!  You need to come to Montvale!   Looks real nice bud.Good job.     So when does the pow/mia come into play?

[TOOLS1]

He has another set of side covers, and  a tank painted with the POW/MIA logos. He puts them on, for special occasions. He is a Vietnam vet. Says they were winning when he left, and he aint got no f@#$%^&* attitude. He gave me his old full face helmet he used to wear back in the 70's. It's really cool. I will have to put up some pictures of it.
TOOLS

[shinyribs]

Very Cool!    Tell him i said "Thanks" for fighting for us.All the respect in the world.

[TOOLS1]

We had the break lines made up. Noticed I used banjo fittings, and bolts on the calipers. The banjo bolts are 10 X 1.25. I had to trim them 1/4 inch, for length, but they work perfectly.
 

 

This is the bike now. Notice the big smile on my buddies face.
 

TOOLS