Slow Monster rebuild

350TSS · 02-01-2017, 06:12 PM

I took the bike down to MADASL to get the exhaust headers made. The original exhaust had a large dent in the front down pipe as a consequence of me riding over a 300mm kerb and grounding/flattening it.
The rear header had to be cut off with a Dremel as the bolts at the first pipe junction were seized and I managed to completely strip the hex on the first clamp. Hammered in Torx bits did not shift it and the only way the Dremel cutter would fit meant the stream of sparks was coming directly at my face - not pleasant.
Mark at MADASL is brilliant he also machined the flywheel and lightened the main drive pinion and the clutch drive gear and the jack shaft gear for the cam drive. It is not possible to machine massive amounts off the early Monster flywheel because of the need to maintain the ignition pick up positions on the flywheel. I think about 2kg became swarf.

02-01-2017, 06:12 PM	#11
350TSS Too much time on my hands member Join Date: Jan 2013 Location: Shipbourne Bike: M900 Posts: 1,419	I took the bike down to MADASL to get the exhaust headers made. The original exhaust had a large dent in the front down pipe as a consequence of me riding over a 300mm kerb and grounding/flattening it. The rear header had to be cut off with a Dremel as the bolts at the first pipe junction were seized and I managed to completely strip the hex on the first clamp. Hammered in Torx bits did not shift it and the only way the Dremel cutter would fit meant the stream of sparks was coming directly at my face - not pleasant. Mark at MADASL is brilliant he also machined the flywheel and lightened the main drive pinion and the clutch drive gear and the jack shaft gear for the cam drive. It is not possible to machine massive amounts off the early Monster flywheel because of the need to maintain the ignition pick up positions on the flywheel. I think about 2kg became swarf.