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Old 05-17-2012, 12:49 AM   #901
Underboning OP
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5/6 Clutch Installation

After having a rather greasy breakfast of some leftover fried dough and coffee, we started getting our tools and tarps together. Once we had everything assembled, we rolled my bike across the street and under the clinic's awning. After draining the oil and removing the leg shield, I removed the oil screen cover and oil screen and then the eight bolts that secure the engine side cover.



A few days ago, I bought a plastic storage bin to use to catch the oil and any small parts that might fall out. I put it under the edge of the motor and then gently tapped on the engine side cover with the wood handle of my hammer to break the seal.



When I pulled off the cover, a fair bit of oil drained out, and a couple of parts fell into the tub. Once I had the side cover off, I removed the clutch lever and cam plate. After that, I removed the clutch outer cover and discovered that there was a gasket between the outer cover and the clutch assembly itself. Since I didn't have a replacement gasket, Re carefully used a thin knife blade to separate it from both pieces. Fortunately, we were able to keep it intact, because we will need to reuse it. With the outer cover removed, I could see our big problem of the day. The clutch unit itself is secured to the output shaft by a special “anti-loosen locknut.” The anti-loosen locknut requires a special tool which we don't have. Basically, the tool is a socket with four prongs that project from it that engage the notches in the locknut.



The locknut sits down in a well in the center of the clutch unit, so getting to it with any other tool is difficult. I unsuccessfully tried to loosen it using a hammer and screwdriver but couldn't get a good enough angle. I knew from viewing a Youtube video on replacing the clutch on a Honda Passport, that the Hondas use a similar nut. So while I worked on removing the gasket from the engine case and case cover, Re walked over to one of the repair shops we'd seen while out walking to see if they had the needed tool. I figured if we couldn't borrow the tool, maybe we could push the bike the five blocks or so to the shop and have them remove the nut.

While she was gone, Robert from reception asked what the problem was. I explained that we needed a special tool to remove the clutch. Fortuitously, Robert's friend, Jacob, happened to be visiting this morning. He came over to look at the problem and said that he had the tool at his house. About this time, Re returned with news that the shop was closed. Jacob said that since it was Sunday, every shop would be closed. I guess I am used to the schedule of motorcycle shops in the US, which are usually open on Sunday and closed on Monday. Jacob said if we could wait for about an hour, he would ride home and get the tools. While he was gone, we finished cleaning up the gasket surfaces and wiped up the oil from inside the cases. Jacob returned with the special wrench and an assortment of other tools and gasket sealants.



With his help, we were able to remove the locknut and get the new clutch unit installed. Since we still needed to get a replacement clutch adjustment bolt, this was as much reassembly as we could do now. We reinstalled the side cover temporarily and cleaned up our workspace. We rolled the bike back across the street and then got cleaned up.

Since it was now about 2:00 pm, we decided it was time for lunch. We took our adjuster bolt with us and walked over to our favorite chicken and rice place. After lunch, we headed up another street that had several motorcycle repair shops on it, but they were all closed. Since it didn't look like we'd get a replacement bolt today, we hit the grocery store for a watermelon. Back in the room, we had some fruit and then a shower. We spent the rest of the afternoon reading, and Re also did some sketching.

Later in the evening, we went out to Kapitan for dinner. On the way back to the room, we spied a GS with Texas plates parked on the main street. The couple who are riding it are Indian and are in the middle of their RTW trip (rideoverland.com). We spent an hour or so talking with Nick about their ride so far and the new problem of getting from Malaysia to Indonesia. Up until two weeks ago, there was an onion boat that would take motorcycles from Penang to Medan, on the island of Sumatra, inexpensively and easily. This was the route that most overlanders would use, but apparently, the Indonesian government recently decided to shut it down. Now bikes must be crated and go by a freight line. This has caught a lot of people out and is a big topic of conversation on HUBB. Nick's plan was to head through Singapore and ship the bike from there, so we told him what we know about the difficulties and expense of that plan. Since they were touring India around the same time that we were, it was fun to compare notes with him. After saying goodbye and good luck, Re and I headed out to the Corner Bar for a nightcap.


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Old 05-17-2012, 12:59 AM   #902
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5/7 Quest for a Clutch Adjuster Bolt

After breakfast, we walked out in search of a new clutch adjuster bolt. There were a couple of bike repair shops on Lebuh Cintra, so that's where we headed. One of the mechanics at the first shop spoke enough English to understand what we needed, but told us we'd need to go to a used parts store. He gave us the name and address of a parts store and sent us off in the general direction. Stupidly, we had forgotten to bring a map with us this morning, so instead, we relied on directions from strangers. People kept pointing us in one general direction, but after an hour of not finding the street, we walked in to another motorcycle repair shop. We asked for directions to the parts store and were told it was at least a couple of kilometers away. Oh. The shop owner asked what we needed, so I showed him the bolt, and he said that if we wanted to come back around 1:30, he would have one for us. He explained that he could get it from a parts store more easily than we could do it ourselves. I asked how much it would cost, and he smiled and said he wouldn't know until he had it. Not knowing what else to do, and really hoping we wouldn't be overcharged, we left the bolt with him and said we'd be back in about three hours.

Re and I walked around and had lunch to kill time. While we were wandering around, Re did buy a box of hair color so she can remain a “natural” blonde. About 1:30, we returned to the motorcycle shop, and sure enough, they had a bolt for me.



It wasn't an exact match, but all of the critical measurements were the same. I winced in anticipation when I asked how much it cost, and I almost laughed when the guy said it was 5 ringgit (1.66 USD). Another thing I love about Malaysia is that we have rarely run into any kind of farang pricing. I wanted to spend more money with the man since he treated me so fairly, so I bought a liter of oil there as well, even though it was priced about two ringgit higher that at our usual shop.

We got back to the room around 3:00 pm, but decided to wait until after 5:00 to install the bolt since the clinic's awning would be free at that time. Shortly after 5:00, we pushed the bike across the street and got to work. We installed the new adjuster bolt in the side cover, and it was a perfect fit. I then used some gasket shellac that Jacob thoughtfully brought by, on both surfaces, and then carefully installed the gasket. After I installed the last couple parts, on the inside of the side cover, Re carefully helped me slide it over the kick start shaft and dowel pins. With the cover in place, it was just a matter of installing all the bolts, the oil screen and cover, and the kick start lever. After that, we reinstalled the exhaust and leg shields. We refilled the engine with oil, adjusted the clutch, and then, nervously, thumbed the starter button. It started up fine – the clutch seemed to engage and disengage normally, and best of all, there were no oil leaks. I wanted to take it for a quick test ride, so while Re picked up the tools, I ran inside to grab my helmet. I jumped on the bike and began rolling it backwards and noticed that it wasn't rolling very easily. I looked back to see that I had a flat rear tire. So we got the tools back out and grabbed one of the spare tubes and got to work. Twenty minutes later, we had it all put back together and then I went for my test ride. Since it was getting late, I only went around a few blocks, but the bike was shifting normally, and even hitting it hard in second gear didn't produce any slippage. By the time I got back, Re had everything picked up, so we went inside for a shower.

Later, we tried a different place for dinner, called Line Clear. Their specialty is nasi kandar, where you get rice and select from a wide variety of toppings. The toppings include fried chicken, curried beef, chicken, squid, prawns, and you can even get a whole, deep-fried fish head. The food was excellent and cheap too. Dinner for both of us was about five bucks. After dinner, we walked into Little India to do some shopping and get some of our favorite coconut candy.



1 mile. Clutch seems great.
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Old 05-17-2012, 06:17 AM   #903
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I remain impressed with your choice of bikes. You have a machine you can repair under an awning of a closed clinic. Nice work and I really hope your clutch troubles are behind you.
Your story and that of Nathan the Postman and others has helped inspire me to go smaller and simpler and I've downsized to 250cc from 1200cc.
Are you thinking of putting together some kind of presentation of your trip that you could share at venues like HUBB rallies?
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Old 05-17-2012, 07:12 AM   #904
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Vancouver is indeed beautiful. We live in Squamish between Vancouver and Whistler.....We do get our share of rain though! My husband and I have ridden to Vancouver on the Majesty and Whistler many times....:-).

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Old 05-18-2012, 06:46 PM   #905
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Clutch repair

I am impressed!!!!!
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Old 05-18-2012, 09:56 PM   #906
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Quote:
Originally Posted by MrBob View Post
I remain impressed with your choice of bikes. You have a machine you can repair under an awning of a closed clinic. Nice work and I really hope your clutch troubles are behind you.
Your story and that of Nathan the Postman and others has helped inspire me to go smaller and simpler and I've downsized to 250cc from 1200cc.
Are you thinking of putting together some kind of presentation of your trip that you could share at venues like HUBB rallies?
We have been loving our choice of bikes so far, especially when we look at and hear about the mechanical problems others have had. That said, if we do stay in the US I will be looking for a 250 myself! I particularly like the new XT250.

As for putting together a presentation, I hadn't really thought about it. Our trip has been roundly ignored over on HUBB, so I've stopped updating the trip report over there. Honestly, most of the RTW crowd seems to be fixated on the idea that "bigger is better" and we've even met a couple of riders who have accused us of lying about some of our trip. Glad we have the pictures!
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Old 05-18-2012, 09:59 PM   #907
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Originally Posted by gasandasphalt View Post
I am impressed!!!!!
Honestly, it was a pretty simple fix, but thanks for the accolades. If we'd have had the special tool and the adjuster bolt it would have been a two hour job. But it is always satisfying to fix 'em yourself!
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Old 05-18-2012, 10:03 PM   #908
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I'm gonna be mechanics like you guys when I grow up! haha.
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Old 05-18-2012, 10:03 PM   #909
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5/8 Beach Day

After more roti for breakfast, we jumped on the bus and headed to the beach at Batu Ferringhi.



We spent several hours at the beach, enjoying the sun and the water, and deciding on a date to return to the US. We need to be in North Carolina by July 7, so we decided to fly to LAX sometime between the 5th and the 10th of June. We've been putting off making this decision since it marks the end of the trip, but we need to book our freight and get our airline tickets, so it had to be done. We're both kind of excited about seeing people at home, but we're also kind of bummed about the end of the trip. Late in the afternoon, we took the bus back to town, took a shower, then headed out for dim sum. After dinner, we went to see “Cabin in the Woods” at the theater.
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Old 05-18-2012, 10:06 PM   #910
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5/9 Lazy Day and Tire Change

We tried something new for breakfast today. It's a Chinese dish that we don't know the name of, made of cubes of rice cake that is fried in a wok with bean sprouts, scallions, fresh ginger, and chili paste. Two foam trays of it cost 4 ringgit (1.33 USD) and it was tasty. Re had a doctor's appointment this morning, so while she went to that, I did some reading and started looking at shipping options from Malaysia. After she returned, we went out for a lunch of chicken and rice.

Since it is Wednesday afternoon, the clinic's awning is free, so we took the opportunity to finally change my front tire.



I am still running the original front tire that came on the bike, but after 23,400 miles, it's looking a little thin. We installed the front tire that we bought in Namibia and a new tube. Not only did the original tire last more that 23,000 miles, but the tube I took out was also the original tube. I removed this tube in Ooty and replaced it with an Indian tube that failed after 1,400 miles. At that point, I reinstalled the original tube (since it was our spare). I'd say I got my money's worth! While we had the tools out, we also adjusted Re's chain and clutch.

With the bike work done, it was time for a haircut. In danger of turning into some kind of long-haired hippy freak, I had Re give me a quick trim. After getting cleaned up, we walked up to our usual motorcycle parts shop and bought two new rear Dunlops. We shouldn't need to use them before the end the of trip, but the Dunlops here seem to be very similar to the ones we bought in India, and they have been great tires. And it doesn't hurt that they were only 16 bucks each. The rest of the day was basically dinner, a little shopping, then a stop at the Corner.
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Old 05-18-2012, 11:46 PM   #911
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You two are my 'RTW' heros....
Carry on in your awesome-ness.... (sp?) and continue to
have a great trip!
Ride safe!

(and the bikini shots don't hurt a bit, hehe )
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Old 05-19-2012, 12:03 AM   #912
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Will be sorry to see the end

Hi Colin and Re,
I have been following your movements every day and wish you well, but I feel like I have been on your journey with you and am sad it is coming to an end.The last few years, I with my wife, have had several trips to Thailand and Vietnam and can only dream of the fun you are having.
Thank you both for the pleasure you have given us all here!
Hope you dont stay too long in the States as I look forward to following your future trips
Robbi
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Old 05-19-2012, 04:29 AM   #913
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Time Fly's

I check this thread every day and have really enjoyed tagging along the voyage through your posts. I've seen parts of the world I'll likely never see in person so I wanted to thank you for all the work that goes into this. I just went back to the first post and realized it was way back in July of last year when you departed! Now that you have made the plans to head back, what are you guys doing with those well travelled Sym's when you get home? Smithsonian? Henry Ford Museum? Hanging from the rafters above the bar in the basement?
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Old 05-19-2012, 04:30 AM   #914
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Quote:
Originally Posted by Underboning View Post
..., . Our trip has been roundly ignored over on HUBB, so I've stopped updating the trip report over there. Honestly, most of the RTW crowd seems to be fixated on the idea that "bigger is better" and we've even met a couple of riders who have accused us of lying about some of our trip. Glad we have the pictures!
Love every installment of your report, and the Re picture bonuses are awesome. They don't know what they are missing at HUBB. Sure glad you are posting here and that I found your well documented, wonderfully photographed Ride Report. You write about the adventure, life's curve balls, and even the "simplest" of bikes can get you there. You cannot end this RIDE.
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Old 05-19-2012, 05:51 AM   #915
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sad to hear that you guys are heading home! Guess we all knew it would end at some point. I know you have to do what you have to do the same as the rest of us, but I have really enjoyed the regular postings and sure wish you both the best in what ever you decide to do! I know that lots of folks including myself enjoy spending time over at the HUBB and it's all good but it does seem to me a little less personal than ADV. This site has become one of my daily routines and it's really due to reading reports from people like the two of you; it reminds me of a good book that I just can't seem to put down. Know that you will be missed and I will continue to enjoy as long as you continue to post. Travel safely and enjoy EVERY minute my friends, you are STILL doing what all of us only dream about!
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