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Discussion Starter · #1 ·
I started the stripdown today...
Actually I was pleasantly surprised how remarkably simple and easy it is to tear down the body panels on the F650ST
ANd also of how "relatively clean" the bike is despite its age .


Now that everything is "peeled off" I can give it a good clean underneath the skin, check for possible leaks,
order parts and concumables and prepare for the major maintenance works.

And I can also start cleaning, de-greasing and prepping the body panels for "Dipping" in matt black.

Pictures say more than words... so here we go !

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Looks like your kitchen is getting cluttered up with bike plastics. I hope no one accidentally turns the stove top on.
The fork stanchions look like they have a fair bit of rust pitting on them, hopefully it is just dirt otherwise there is a fair bit of sanding and polishing work to do.
Have fun with the work and the bike.
Pete
 

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Discussion Starter · #3 ·
Yeah the kitchen is a nice dry and warm place to store that ... Lol
About those forks, good observation but indeed it is 98% dirt in the oil that was leaking from the forks, and new seals + dust caps are on their way. For sure I will do a thorough cleanup before reassembling. Have the ultra fine steel wool ready :) I'm hoping to give the plastics a good wash and rinse today and then I can get on with coating them in SprayPlast later this week.
I have a 12v+USB handlebar socket, GPS, Cell phone holder etc... ready and a VDO voltmeter standing by... So plenty of little things to do over the next few days and week(s). Fortunately the engine and drive train are ok. Solid basis to work from.
 

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Discussion Starter · #5 ·
And then the fun began... Bring out the spray cans (SprayPlast) and et buzzzzzy.

You'll notice that some parts are matt black and others more "shiny".
The shiny ones were already black plastic so the just got a clear coat of the SprayPlast (equivalent to PlastiDip) coating
The parts tha t were yellow got the matt black spray treatment.

I hope this will turn out OK and I'll have a nice, sober, black and "Bad-Ass" bike....

I kind of over-estimated the capacity of the black spray cans, so as a result I was not able to apply 6 or 7 cotas to all parts.
I'm now waiting for another can to arrive so I can finish the job.

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Discussion Starter · #6 ·
Nice one, looks really good.
By the time you've finished how many cans will you have used? This will give a more accurate coverage rate than the manufacturers figures.
Thanks
When this ppupy is all "painted", I will have used the following :
  • 3 cans of 500 ml matt black for the yellow plastics (and I got a 4th one as spare for touch-ups)
  • 1 can of 500 ml clear coat for the parts that were already black plastic (also have a spare just in case)
I am putting down 2 very thin coats (to start the adhesion process) and then 2 medium (for coverage) and 2 heavy (for thickness and smooth "removability") coats on all the parts. So 6 coats in total
 

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Discussion Starter · #8 ·
I can hardly wait for the extra cans to arrive so I can finish up the paintwork.
And then replace the fork seals , drain and replace all liquids (oil, fork oil, coolant, brake fluid,...) Put in all new filters, spark plugs and get that beast reassembled, stickered up and on the road. Hoping that early next week I'll have my license plate and the indurance all sorted out. Yeah, Baby, Yeah.... I have had over a dozen bikes over the last 3 decades, but it is always exciting to get it on the road for the first time after the checkup and maintenance..

By the way, here is last year's project... KZ250 from 1980 (all digital dash / LED / fresh ...) That one will probably come up for sale in a few weeks or so. (In thsi pc, the exhausts had not been wrapped yet)
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Discussion Starter · #9 ·
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Some more small things.... Added some wiring for voltmeter, driving lights, 12v and USB outlets, switch and LED indicators. And next up is the engine crash bar set.... Sanded and covered in 2 coats of primer. Hope I never need it in an actual crash, and just use it for looks...
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Looks good Dani, what did you do about a temperature guage. My bike had a temperature guage where you have put the voltmeter, I have heard that some had a clock there instead.
Pete
 

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Discussion Starter · #11 ·
Looks good Dani, what did you do about a temperature guage. My bike had a temperature guage where you have put the voltmeter, I have heard that some had a clock there instead.
Pete
Hi Pete,

Mine had a clock there, which was not really working as it should. So I decicded to remove the clock from the housing, 3D print an adapter in which I could fit a mini LED voltmeter and 3 extra LEDs, put that in, put some "mirror finish" adhesive foil on the inside of the glass, then glue it all together again and mounted it back in the dashboard/cockpit. The temperature monitoring on 97 ST is just a red temp indicator light on the right hand side of the dash, in the indicator light cluster.

The 3 LEDs show the status of ...
(1) the lights : on/off (Red LED on top of the voltmeter)
(2) the extra driving lights mounted on the front (White LED below voltmeter)
(3) the 12V and USB outlets mounted on the handlebars (Blue LED below voltmeter)

The old clock mechanism has now been added to my ever growing collection of "one-fine-day-I-will-fix-this" re-useable items. :)

PS/ dont mind the lavender pink colour of the 3D printed adapter... It was some leftover PLA filament which I spray painted black anyway... :) :)

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Discussion Starter · #12 ·
The "Crash bars" have been removed, sanded down, treated agains rust , primed and had their initial coat of paint.
3 or 4 more coats of gold and then 3 coats of (matt) clear laquer to follow...
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Discussion Starter · #13 ·
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Starting to come together....
Slowly but surely, but surely slowly.
And while all wiring is exposed, I added a trickle charger cable with a 3 pin XLR connector. Always nice to be able to "plug and charge" while it is in the garage. Have that on most of my bikes...
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