Scott's '82 Magna restoration project - start to finish

[grandpaul]

Just back from the painter's, it looks like tomorrow is "brake and clutch" day...

[Jigger]

Your doing one hell of a job on it. I can't wait to see the finished product. If you can take a video of it starting up with a circle check of the bike.

[grandpaul]

I've not had good success with video, seems like a 20-second video is 20 megabytes and never can get them to upload...

[grandpaul]

First brake caliper partially re-assembled-



The pistons are buggers to get in past the first new double-lipped seal; even bigger bugger (say that fast three times) is inserting the floating shaft and it's two rubber booties into the caliper mounting lug! I figured out the trick - lightly grease and insert one bootie in place in it's groove, install one bootie on the shaft, then slip it out of it's groove far enough to be able to work the larger outer lip into it's place in the other caliper mount groove, then push it fully home (not easy, as it's a VERY tight squeeze to get it in and past the lips of the 1st and 2nd bootie). This probably doesn't make sense unless you have the parts in front of you and try it.

Both calipers done, with all the little dust booties replaced on the carriers-

[grandpaul]

Front Brake & Clutch master cylinders done-





No suprises, no drama, just like new.

Now waiting for UPS to show up with the new braided stainless brake lines...

[grandpaul]

Got a few items checked off the list, it's almost down to just the two operational issues - coolant leak & fuel pump.

Sidestand and rear brake springs installed, replacement speedo, mirrors & cruiser pegs installed, new horns set up, just need to wire them into a new relay. Front brake line splitter installed, just waiting on the new brake hoses & grips now.



New speedo will necessitate a mileage differential note in the shop manual-

[hop along]

I've been following your process with great interest and enjoying the great detail photos as you move along.  Thank you!

If I can ask one question: I'm unfamiliar with the brake setup in the below photo... what is the dial near the bottom left with the numbers 1, 2, 3, 4.... it looks like there is a type of trunnion assembly?

Thank you... and keep up the great work.  It is obvious there is a lot of focus going into this effort!
Hop Along

[grandpaul]

If I can ask one question: I'm unfamiliar with the brake setup in the below photo... what is the dial near the bottom left with the numbers 1, 2, 3, 4.... it looks like there is a type of trunnion assembly?

That's the braking anti-dive mechanism. Very ingenious, the upper caliper mount is free rotating, and the lower pivot allows a miniscule amount of fore-aft travel to exert pressure on the anti-dive plunger, causing it to restrict the compression damping as the bike starts to dive under braking forces. The rig is adjustable for rider weight and preference/feel.

[hop along]

!  Got it!  Thanks for the description!  I just read about such a thing in a motorcycle magazine... maybe Rider or Cycle World, forget which.  Now it all fits in my head and makes sense 
Pictures CAN be worth many words...
Thank you,
Hop Along

[grandpaul]

All that's remaining is the front brake lines and a set of grips; brake lines should be here tomorrow, I'm going to install a temporary set of grips so Scott can choose whatever he prefers.

So close...

[grandpaul]

One thing for sure, those dual Fiamm horns BLAST OUT!!!

[grandpaul]

A little "before & after" comparison-

[lragan]

Well, its a good thing you showed us the intervening pictures -- I would have bet money they were not possibly the same bike.

Good work.

[guywheatley]

That thing is gorgeous. Great job.

[grandpaul]

Handy location for the new horn relay with in-line fuse (just above the battery)-



New starter button made from an old horn button, trimmed, drilled & JB-Welded in place-



I painted out the little horn icon and yellow line, just need to run to Wally World and get some white model paint to draw the little circular arrow. (or is it supposed to be red?)