The Polish rebuild

[Steff]

Yup this time I got very lucky all good in there. The new tank had a couple of dings which I managed to massage out with a wooden dowel through the pump opening.
I need to take the radiator off to straighten the fixings and maybe tomorrow I will fire her up again.

Is that normal the bike requires a little cranking from cold? Bit too much for my liking. Once it comes to life idle regulation etc all works as supposed. On ignition I can hear the stepper adjusting constantly so I think it can be the nature of things. Once it has run a moment it starts immediately afterwards.
Me thinks it might want some adjustment for the cold start however the idle is nicely elevated so tge stepper is doing its job before bringing it down to roughly steady 850rpm where it stays rock solid.

Also - when looking under the tank. There are three free plugs. I am guessing this could be the fuel gauge, clock and??? The top one with the yellow insert seems like could have been used since there is green residue characteristic of water plus electricity galvanic thing. Am I missing something in there???

Same with my 2006, with the cranking in cold weather. Been OK all summer; now the temp has dropped. It'll be interesting to see what it's like when it gets minus here. Did you sort yours?

 

[Kevin frazier]

Seems like there is nothing to it. Apart from the fact I need to take BOTH wheels and keep the bike suspended for a month or so
The spline lube is something I am used to having owned a number or Beemers. I have a bike lift/stand - it should do the trick - has been holding a GL1200 during rebuild for a couple of months - should be fine with the Rocket.

Checked the manual for FD oil capacity - 170ml - dunno if 70ml has been drained so definitely not overfilled. Wonder why so little - there has been no sign of leakage.
Need to get some crush washers for both of the fill/drain bolts. There were none which just blows my mind. The magnetic plug had the traditional sludge on it - no solid particles which is good. Will keep you posted.

The diff doesn’t have use crush washers, if you crush a crush washer to seal on the drain bolt, the drain bolt is going to break, the hugh 10mm fill bolt does not get a crush washer, if oil comes out you are to full, but it never just leaks anyway. Set the bike level, fill until fluid comes out fill hole. Thats it, done it 357 times, i change it often. I have never had a diff problem. Ive tore up many other parts, but not a diff

 

[Kevin frazier]

Same with my 2006, with the cranking in cold weather. Been OK all summer; now the temp has dropped. It'll be interesting to see what it's like when it gets minus here. Did you sort yours?

What are your throttle bodie balances, 1, 2 ,3 ? What is tps and stepper set at? Numbers you have to know.