Made a start on fitting Hyde oil filter and cooler, and finding out why rear brake is jammed solid.
Got as far as fitting the oil cooler and bracket, which inserts into the front engine mount with new spacers provided in the kit. Fitting it all in and lining up the various holes so the mounting bolt can go back in is a bitch of a job. The frame downtubes squeeze quite firmly on the spacers and they have to be sprung apart with a tyre iron against the crankcase nose before anything can be lined up. Then of course I fitted the bracket upside down, so it all had to come out again. Don’t do this at home. By this time the engine bolt threads were so damaged from being used as a battering ram to line up the spacers with the bracket that a lot of careful thread filing had to be done before its nut could go on. Next time this bolt comes out, I shall need to replace it with a new one.
Apart from that drama, the oil cooler kit seems to fit okay. I’d also ordered a Hyde filter kit but Pom Bombs (British Motorcycles and Spares) in their wisdom had instead sent me another brand, “TT”. It is an external type with spin-on element that clamps to the frame tube above the swing-arm, and is on the pressure (return) side of the oil pump (which is supposed to be a Good Idea).
It’s apparently best if the gearbox outer cover comes off to install the kit’s oil hoses, and this is a tad inconvenient because of all the other things (header pipe, foot-rest) that have to come off first. Hopefully while down there I may find the source of all the oil that is still pissing out from the undercarriage.
Removed the rear brake reservoir, master cylinder and caliper, the idea being to inspect, thoroughly clean, replace seals, and re-assemble. Had fun and games removing the master cylinder, which in fact cannot be removed at all until the rear wheel has been taken out. This is because the cylinder has to slide off its top mounting bolt (you can't withdraw the bolt) and the tyre gets in the way.
The fluid reservoir alloy has gone all soft and rotten – a wire brush just eats into it. Battery acid? It is very close to the battery breather. Its hose has been quietly chafing on something and is nearly worn right through in several places!
The reservoir and master cylinder are both encrusted inside with dark-brown gunk, and need thorough cleaning. I tried but failed to dissassemble the master cylinder to replace its seals. The set-screw wouldn’t budge until I applied heat (gas stove). The cylinder wouldn’t unscrew at all from its mounting bracket. My efforts to free it while holding it in the vice by its flats only resulted in distortion of the hose-exit orifice. It is now a complete write-off. The caliper looks to be okay – both pistons can be moved.
