Garage Party at Hawks, Sat., Sep. 29

[hawkvtx]

Wasn't sure where to put this so I put it here and over in Tech Talk but ... Just in case anyone is interested. A buddy of mine and I will be doing some work on my brother-in-laws Magna this Saturday at my place in Scottsboro AL. Drop by if you're in the neighborhood. We'll be replacing a rear brake master cylinder and fork seals for sure plus whatever other issues we may run into. Send me a PM or post up here if you might drop in and need any info.

[Nice Goat]

About what time are y'all getting started?

[hawkvtx]

About what time are y'all getting started?

around 10am

[hawkvtx]

Well we got through with the Magna...sorta. After a little trial and error on the right fork we got it apart and new seal and oil in it. The left one took only about 30 minutes since we knew what we were doing by then. The front brakes were seized and we got that taken care of too. Got the rear tire on and serviced the final drive. The part we got stumped on though was the rear brake master cylinder.  Not that it can't be fixed but I can't figure out for the life of me how to remove the old one. There's a connecting rod from the pedal that connects at a pivot point to the other rod that goes into the cylinder. At that pivot point the two separate rods are connected by a u-joint and a small pin that is held in place with a cotter pin. The pin has to be removed in order to separate the two rods and remove and replace the master cylinder. Easy enough right? Well no. Mother Honda in all her engineering wisdom decided that little pin should be right up against the collector for the exhaust system. Thus not allowing any physical space to pull the little bugger out.  Google and YouTube searches yielded no advice.
So any current or previous Magna owners out there ever had to deal with this?  Is there any way to remove that pin without removing the entire exhaust system? Keep in mind there's a couple of reasons I didn't just pull the exhaust out. First, the exhaust on the Magna is fairly complicated and is not just a matter of loosening a couple of acorn nuts and second, all the bolts and nuts that are holding it in place are severely rusted. It's a 34 y/o bike so...ya know , it's got some rust.  There are only three things that can happen when dealing with rusty parts like that and two f them are bad. Hoping someone might have some suggestions.
Oh and I thought about cutting the pin off with my Dremel but again there's not enough space to get to it. I also didn't want to cut into the collector with the Dremel and create even more problems.  The bike itself is pretty solid for one that old.  It's ridable as long as you don't plan on using the rear brake. 

[springer]

Well we got through with the Magna...sorta. After a little trial and error on the right fork we got it apart and new seal and oil in it. The left one took only about 30 minutes since we knew what we were doing by then. The front brakes were seized and we got that taken care of too. Got the rear tire on and serviced the final drive. The part we got stumped on though was the rear brake master cylinder.  Not that it can't be fixed but I can't figure out for the life of me how to remove the old one. There's a connecting rod from the pedal that connects at a pivot point to the other rod that goes into the cylinder. At that pivot point the two separate rods are connected by a u-joint and a small pin that is held in place with a cotter pin. The pin has to be removed in order to separate the two rods and remove and replace the master cylinder. Easy enough right? Well no. Mother Honda in all her engineering wisdom decided that little pin should be right up against the collector for the exhaust system. Thus not allowing any physical space to pull the little bugger out.  Google and YouTube searches yielded no advice.
So any current or previous Magna owners out there ever had to deal with this?  Is there any way to remove that pin without removing the entire exhaust system? Keep in mind there's a couple of reasons I didn't just pull the exhaust out. First, the exhaust on the Magna is fairly complicated and is not just a matter of loosening a couple of acorn nuts and second, all the bolts and nuts that are holding it in place are severely rusted. It's a 34 y/o bike so...ya know , it's got some rust.  There are only three things that can happen when dealing with rusty parts like that and two f them are bad. Hoping someone might have some suggestions.
Oh and I thought about cutting the pin off with my Dremel but again there's not enough space to get to it. I also didn't want to cut into the collector with the Dremel and create even more problems.  The bike itself is pretty solid for one that old.  It's ridable as long as you don't plan on using the rear brake.

For the rusted parts try Aero Kroil;
https://www.amazon.com/Kano-Aerokroil-Penetrating-aerosol-AEROKROIL/dp/B000F09CEA/ref=sr_1_3?ie=UTF8&qid=1538516272&sr=8-3&keywords=aero+kroil+penetrating+spray
That stuff is amazing.
For Phillips head screws, bolts remember the Japanese Phillips head is really a cross head and is different than our Phillips head. They look about the same to the naked eye but you can strip the head very easily using an American Phillips screwdriver.
https://www.amazon.com/Hozan-JIS-4-JIS-Screwdriver-3rd/dp/B00A7WAHTU

The reason for all that /\ is from what I have been told, removing the exhaust might be a pain but for some jobs on the Magna, it is the only way.

Something else I have found useful for rusted bolts is this;

https://www.amazon.com/dp/B01F5XOFFM?aaxitk=kzaqjrwqu4U171HsorOdYw&pd_rd_i=B01F5XOFFM&pf_rd_m=ATVPDKIKX0DER&pf_rd_p=54dc821a-0937-4e6f-9da9-f8dd5443145d&pf_rd_s=desktop-sx-top-slot&pf_rd_t=301&pf_rd_i=impact+driver&hsa_cr_id=9892671770101&sb-ci-n=asinImage&sb-ci-v=https%3A%2F%2Fimages-na.ssl-images-amazon.com%2Fimages%2FI%2F91OCH79I-4L.jpg&sb-ci-a=B01F5XOFFM

You will have to find a  Japanese Cross Head bit.

https://www.amazon.com/Impact-Screwdriver-Vessel-Heavy-Japan/dp/B077CCVMDD/ref=sr_1_5?s=hi&ie=UTF8&qid=1538517443&sr=1-5&keywords=JIS+cross+point+bit 

[kylepeterson]

Well we got through with the Magna...sorta. After a little trial and error on the right fork we got it apart and new seal and oil in it. The left one took only about 30 minutes since we knew what we were doing by then. The front brakes were seized and we got that taken care of too. Got the rear tire on and serviced the final drive. The part we got stumped on though was the rear brake master cylinder.  Not that it can't be fixed but I can't figure out for the life of me how to remove the old one. There's a connecting rod from the pedal that connects at a pivot point to the other rod that goes into the cylinder. At that pivot point the two separate rods are connected by a u-joint and a small pin that is held in place with a cotter pin. The pin has to be removed in order to separate the two rods and remove and replace the master cylinder. Easy enough right? Well no. Mother Honda in all her engineering wisdom decided that little pin should be right up against the collector for the exhaust system. Thus not allowing any physical space to pull the little bugger out.  Google and YouTube searches yielded no advice.
So any current or previous Magna owners out there ever had to deal with this?  Is there any way to remove that pin without removing the entire exhaust system? Keep in mind there's a couple of reasons I didn't just pull the exhaust out. First, the exhaust on the Magna is fairly complicated and is not just a matter of loosening a couple of acorn nuts and second, all the bolts and nuts that are holding it in place are severely rusted. It's a 34 y/o bike so...ya know , it's got some rust.  There are only three things that can happen when dealing with rusty parts like that and two f them are bad. Hoping someone might have some suggestions.
Oh and I thought about cutting the pin off with my Dremel but again there's not enough space to get to it. I also didn't want to cut into the collector with the Dremel and create even more problems.  The bike itself is pretty solid for one that old.  It's ridable as long as you don't plan on using the rear brake.

how about a picture of this wonderful point of interest?

[hawkvtx]

how about a picture of this wonderful point of interest?

this is the little bugger