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T-Cat Project

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T-Cat Project Empty T-Cat Project

Post  SpeakForYou on Fri Apr 25 2014, 02:30

So I knew the previous owner of this bike (family member) who had it for a few years. Sat around for a while before he got it back on the road last June, failed it's MOT due to binding brakes and also the chain was knackered. So he got the brakes fixed and fitted a new chain, only for it to snap a few weeks later on the motorway. Chain took no prisoners and snapped the mud/chain guard, smashed off the left rear indicator and took the reg plate clean off. When I went to see it, it looked as if the clutch cable was snapped. Didn't think there would be too much work but how wrong was I???

Trying to get it ready for it's MOT:
T-Cat Project 146

In back of van shortly after chain snapped:
T-Cat Project 20130723_155817

Sitting neglected:
T-Cat Project 2014-02-28%2017.16.37

Now in my garage, started taking seat off and fairings:
T-Cat Project 20140114_185651

Took tank off to remove airbox to gain access to the Carbs:
T-Cat Project 20140114_194720

Carbs:
T-Cat Project 20140114_194953

Got it into college, gave it a wash. Never knew it was silver haha:
T-Cat Project 20140326_102239

Up on the ramp:
T-Cat Project 20140402_153818
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Post  robertcains on Fri Apr 25 2014, 06:55

Looks tidy, clutch problem will most likely be a broken pushrod from the snapped chain, easy fix (unless you do it the hard way like Rosco lol)
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Post  SpeakForYou on Fri Apr 25 2014, 17:05

Aye pushrod was snapped in 3 haha. One of the lecturers in my college is in the middle of making me a new one which saves abit of money.

Preparing to remove the annoying Datatool Alarm:
T-Cat Project 20140327_092905

Checking out the day soldering/wiring:
T-Cat Project 20140328_101236

T-Cat Project 20140328_101220

T-Cat Project 20140328_101137

T-Cat Project 20140328_101115

T-Cat Project 20140328_101056

T-Cat Project 20140328_101121

Finally cut it out:
T-Cat Project 20140328_111322

Just had to solder the wires together and put a bit of heat shrink/insulating tape round them.
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Post  SpeakForYou on Fri Apr 25 2014, 19:41

Took off the front sprocket cover to check clutch cable:
T-Cat Project 20140327_102416

Found a few extra bits, broken pushrod:
T-Cat Project 20140327_102406

Front sprocket could do with a bit of a clean:
T-Cat Project 20140327_102401

Drained oil and removed clutch cover to gain access to clutch basket:
T-Cat Project 20140402_153805

Clutch plates:
T-Cat Project 20140402_153808

View of bike so far:
T-Cat Project 20140402_153802
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Post  mikeyzf600 on Fri Apr 25 2014, 21:20

Nice progress so far. Lucky the chain didn't do more damage, you hear stories of it going through casings and all sorts!

Regards

Mike
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Post  SpeakForYou on Fri Apr 25 2014, 21:49

That was my worst fear but started it up and the oil only leaked out were the pushrod was. Very lucky.
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Post  Guest on Sat Apr 26 2014, 09:01

Nice work! And on a side note, those exhaust headers/downpipes are in good nick.
Don't think I've seen any in that good condition lol.
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Post  SpeakForYou on Sat Apr 26 2014, 09:12

Lol, will eventually get them polished but concentrating on the mechanics first. Hope to get various bits powder coated and painted bit wont be for a while yet.
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Post  0ldcat on Sat Apr 26 2014, 15:28

T-Cat Project Pro-bo10

Nice tidy bit of soldering there  Billy Whizz

 rofl 

Good progress on the bike so far though, . . . you'll have it shipshape in no time  Thumb 
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Post  SpeakForYou on Sat Apr 26 2014, 15:30

Yep even my first attempt looked better than that lol!
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Post  SpeakForYou on Tue Apr 29 2014, 00:59

Shifted bike to a different ramp so I could remove the swingarm:
T-Cat Project 20140403_135350

Swingarm was rusted to bits:
T-Cat Project 20140403_135444

So home it went and got a run over with a wire brush and sanded down:
T-Cat Project 20140415_155642

Coated it in Ku-Rust:
T-Cat Project 20140419_165236

T-Cat Project 20140419_165232

Primed it:
T-Cat Project 20140420_150055

T-Cat Project 20140420_150102

Painted it Matt Black:
T-Cat Project 20140423_100655

T-Cat Project 20140423_100659

Was originally Gloss Black but ran out of paint and when I went back to buy more all they had left was Matt  sad Had to repaint it all again. Lesson learned, always buy 2 cans. Wasn't to bad considering it was Pound Shop paint.

Stripped down the linkage before fitting. Bearings were rusted so got them cleaned up and rolling again.

Cleaned all this up too. But no after pic:
T-Cat Project 20140403_135414

Finally greased everything back up and refitted swingarm:
T-Cat Project 20140424_113826

T-Cat Project 20140424_113839
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Post  Guest on Tue Apr 29 2014, 06:42

Nice work! Maybe paint those chain tensioners to match?
Maybe I'm OCD?  pmsl 
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Post  SpeakForYou on Tue Apr 29 2014, 06:55

One of the tensioners has bits missing so will wait until I can find another before doing that.
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Post  stretchie_ on Tue Apr 29 2014, 09:45


I think a previous owner of your bike was also the previous owner of mine  green smile

**EDIT**

Oh, loving your work with the swingarm too
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Post  Robcat on Tue Apr 29 2014, 21:05

Don't think we've had such a detailed strip down of a Cat before, but I'm glad you are putting your heart into it. Some certain lad on here (%@? R o s s/!+) probably wouldn't mind you working on his bike. Be a fine bike when it's all finished.

Love your workshop though, think most of us on here would like a set up like that. Lucky to have a college that does bike mechanic's as a subject.
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Post  SpeakForYou on Tue Apr 29 2014, 21:06

That's our new workshop, was finished in November. It's great haha.
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Post  yamahamad on Tue Apr 29 2014, 21:28

Keep up the good work it will be a cracking bike when finisher.

Paul
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