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Thread: R90S barn find caliper cap removal, fairing removal

  1. #1

    R90S barn find caliper cap removal, fairing removal

    Using a torch and Kroil I managed to get one caliper cap nut off. The other one will not budge. The bike sat for 20 years and during that time brake fluid leaked out and dripped down the caliper and onto the alloy wheel, corroding it. I can imagine what it did to the cap nut. Looks like I'll either have to remove the forks and/or get a lift, drill through the cap nut and try the largest easy out I can find. The bike is so low to the ground I can't easily see what I'm doing.

    On another note, I do not have an ignition key for the bike. I'd like to remove the fairing to make access to the headlight and lock easier. I removed the turn signals but do not want to bend the fairing over the signal posts. Any ideas about how to remove the fairing without damaging it? Many thanks.

  2. #2
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    Quote Originally Posted by ruzneb View Post
    Using a torch and Kroil I managed to get one caliper cap nut off. The other one will not budge. The bike sat for 20 years and during that time brake fluid leaked out and dripped down the caliper and onto the alloy wheel, corroding it. I can imagine what it did to the cap nut. Looks like I'll either have to remove the forks and/or get a lift, drill through the cap nut and try the largest easy out I can find. The bike is so low to the ground I can't easily see what I'm doing.

    Before you drill and easy out, give the Kroil a day or so to work. Tap the nut with a hammer.

    On another note, I do not have an ignition key for the bike. I'd like to remove the fairing to make access to the headlight and lock easier. I removed the turn signals but do not want to bend the fairing over the signal posts. Any ideas about how to remove the fairing without damaging it? Many thanks.
    Stretch one side at a time to slip it over the turn signal posts. That's the standard.

  3. #3
    Try a mix of acetone and ATF on the cap. I usually apply it twice a day for a week. If it doesn't come loose then, apply heat -- carefully if you use a torch as the mix may catch.
    '61 Clubman's Gold Star, '13 690 Duke, '13 Daytona 675R, '14 Street Triple R, '17 1290 GT (gone but not forgotten: '76 R75/6, '84 R100, '76 R90S)

  4. #4
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    My S fairing has been on and off so many times it finally developed a crack. Every time I look at it I always think, maybe I could make a useful change/improvement? It's no good cracked. Next time it may bust.

  5. #5
    Airmarshal-IL James.A's Avatar
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    O.K., try this. Remove the top yoke so that the headlight ears are floating. Remove the turn signal pods. You should be able to get the turn signal stems off the roll pins and rotate them forward as you pull the fairing away. There will be a limit to how far forward you can go, but it reduces the amount of stretch needed to dis-engage the fairing from the signal stems.A few extra hands are helpful for this procedure.
    1973 R75/5

  6. #6
    Registered User lmo1131's Avatar
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    O.K, try this.... post all of your questions about your barn-find project in an ongoing discussion thread.

    As more and more people become familiar with your project, the post-page count will go up, and it becomes easier for folks to find your project.

    Just sayin'.
    "It is what you discover, after you know it all, that counts." _ John Wooden
    Lew Morris
    1973 R75/5 - original owner
    1963 Dnepr

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