75b Frontend redo and deep clean

I’m reiterating how much easier to see reconnecting the wiring after seeing 5t’s advice to paint the inner headlight bucket white.So much better on old guy eyes.😁👍
 

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Went with a shy 7oz of 15w fork oil in each tube.For the puttin around I do these days I believe it’ll be fine.Time to start a slow charging of a new last season battery.It’s recliner time.😴
 

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I dropped rotor off at machine shop for a “dust grinding” as the
machinist called it to dress it up.Rotor was still in decent shape per the machinist.Upon its return I’ll be looking forward to wrapping this 75b front end redo up.
 

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Decided to spray the underside of fender with the hammered finish after prepping while it’s apart for polishing.Chased the threads then plugged the holes with bolts before spraying.Down to one little table of parts.Master cylinder and caliper rebuild left to do.
 

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Just split the caliper.”Yowzer”,the front brake has actually worked quite well.🤷‍♂️.Definitely time for some attention.
The PO told me he’d replaced the brake pads shortly before I bought it.He’d not had it long and was 2nd owner.By the gouge in the piston wondering if they were froze and he’d tried to free them with a chisel?🤷‍♂️Is this a familiar site to those thatve done many?
 
Able to pick the original rotor up this afternoon already from the machine shop.Has the finish I’d been anticipating.Very pleased.Gonna leave the caliper pistons soak a bit in PB blaster before I even try any of the great tips to remove.
 

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Even the very smalls ;after a common cleaning,mist them with a coat of clear.Both sides.TMI,Hope so.
 

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Decided to just order a new caliper from xs650 direct and get it done.Looks authentic and not crazy priced.By the time I get a rebuild kit and install it it’s not that much more and I’ll use the old one on another one day I suspect.Time to be done.
 

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Decided to just order a new caliper from xs650 direct and get it done.Looks authentic and not crazy priced.By the time I get a rebuild kit and install it it’s not that much more and I’ll use the old one on another one day I suspect.Time to be done.
Yes, by the time you factor in stainless steel pistons, seals, cleaning and powder coating etc.... It's not a lot different in cost to buy one of the aftermarket calipers. They look a pretty good match for the originals.
 
I had to keep my word that I wouldn’t remove the motor this close to riding season.A lot of tidious taping to freshen up the silver on the upper case.Waiting on the new caliper from XS650 direct to conclude the front end redo.Expecting it tomorrow.
 

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Not a normal practice to do this while the motor is still in.Very time consuming.Absolutely no room for prep error.The Dremal is definitely your friend doing this way.Very risky if there is any lifting after clear.It’s a mess to reprep and recoat.Ask me how I know?lol.This time all is good.She wins.😅
 

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