RH engine rebuild

[lambs]

This is the reason I need another front guard:



This is the front guard from RH#2.   The cracking was hidden beneath an aftermarket fork brace.    The guard is actually 'bulging' in the region of the cracking.    It's caused by corrosion (rust) between a metal brace that's part of the guard and the guard itself.

Anyway, I think I've tracked down another guard.   Not exactly the same, but will do the job.

Frame is out being done.

[lambs]

gotta grind the shaft shorter

...so, as I observed, the stock parts can't be fitted without splitting the cases or 'modification'.   It's like saying.... "yeh, that bearing fits.....but I had to use a sledgehammer....."

Not my style, I'm afraid, no offence.

Anyhow 1196 needs undercut 1st and 2nd cogs coz full-gas
will soon enough round-off the stock cogs in a rattly machine-gun sound of destruction jeeves...

The dogs were fine and unless the undercutting is done properly you'll weaken the dogs and the gear (I once investigated a gearbox failure for a certain well-known Australian manufacturer caused by exactly this issue).      In my opinion, not necessary on something to be used very occasionally and otherwise stock - 1196 notwithstanding.   If you're going racing or this is a daily.....knock yourself out.

Also 80' cams are superior to 78' cams for the street/road,
  78 cams are too bloody fluffy below 3 grand ...

I'm not using '78 cams, but friends with early bikes 'back in the day' never commented about anything like that.   They were stock bikes and I had a short ride on one.   No problems, AFAIC.

[pgnz]

kick gear/shaft can be slipped in without pita
 case splitting but gotta grind the shaft shorter
 in conjunction with some sleight-of-hand...
 Leaves a smaller width "support" at the end but
 meaningless as there's basically zero load there
 anyway ..

 possibly after 40 or 50 million kilometres
 of gear-changing it could cause 0.5 - 1mm of wear though..
 Will report back about that around the year 2220 or so..

For convenient tired-battery-backup-kick-lever -
a fold-up xs850 lever fits with a chainsaw-file
 groove to spline for the lock-bolt. ..
 position and clearance of footpeg determined by year of model,
 fold-up pillion peg can be adapted...
 Torquey-as 1196 wiseco kit sweet to flow and tulip the
 ports with it...

Anyhow 1196 needs undercut 1st and 2nd cogs coz full-gas
will soon enough round-off the stock cogs in a rattly machine-gun sound of destruction jeeves...
 Also 80' cams are superior to 78' cams for the street/road,
  78 cams are too bloody fluffy below 3 grand ...

[lambs]

One small problem found when I went to bolt on the intake manifold 'stubs'.     Part of the head casting interfered with the #4 intake stub...



....preventing the stub bolt holes lining up on the head....



About 3mm misalignment.    Rather than attack the head I took a little off the stub and everything lined up fine:



Not really a big deal.     None of the other stubs had this problem.    The stubs were a new set for an XS head, so maybe the XJ stubs are slightly different in order to fit but I'm not about to buy an XJ set to find out.      From pictures on the internets it appears XJ stubs come with gaskets, which is another difference.

[Christian Raith]

Cleaned up and painted the engine side covers:



VERY nice

[lambs]

Cleaned up and painted the engine side covers:

[lambs]

Sucks to be in Vic if you haven't got a compliance plate ay.  .

.....thus why I am so keen for the one I have to be readable.     I have no reg history for this bike....nothing 

[Jonesy :-)]

Sucks to be in Vic if you haven't got a compliance plate ay.  .

[lambs]

I didnt even need a compliance plate for historic rego in nsw

VicRoads has tightened things up in Vic since the 'good old days' when 1 person in a club could sign off on the bike or car without a RWC.

Basically it boils down to:

- proof of previous full reg history in Australia (any State or Territory).   Previous club reg (only) or similar is not enough.

and/or

- proof of ADR compliance.   Ideally an ADR plate that matches the frame number, but an engineering inspection report or compliance plate (eg Qld L03 compliance plate) is usually OK.

+ a current RWC, of course, except for anything pre-1949.

If it's a grey import manufactured after June 1975 then it won't have an ADR plate, of course, and without proof of previous full reg VicRoads will demand an engineering inspection (called a VASS) costing at least $440.

I'm a scrutineer for club reg in Vic and I can actually do an inspection report on my own bikes, but that still has be signed off by the club Vicroads signatory, and, believe me, with VicRoads it's best to have all your ducks in-line.....

[Jonesy :-)]

I didnt even need a compliance plate for historic rego in nsw

[lambs]

Ordinary old thinners will melt it away, all be it slowly.

I had some MEK left over from another job, so it was worth the try.

[makzy]

Ordinary old thinners will melt it away, all be it slowly.

[lambs]

Moving on from powder-coating......I was able to remove the powder coat from the ADR plate with MEK and a 'few' cotton tipped buds.....



Should be enough to get through classic reg in Vic.

Finished the bracket before final welding:



The 'pin' is made from a 6mm coach bolt with the head reshaped to match the original as closely as possible.



Bracket and pin welded in place and trial fit of the sidecover:



....just like a bought one (sort of....).

I'll be taking the frame and other parts (swinging arm, stands, etc) to be stripped later this week with any luck.

[makzy]

That’s rite Jonesy, I used to work in the industry, not as a powder coater but as a fitter in the balustrade industry, but the business would coat anything, the procedure was blast, wash, dry in oven, chemical clean, prime, bake, sand lightly, clean again, powder coat, bake, cool, test thickness.the carry racks on my Ute were done by them 16 years ago and still good apart from the top bit where everything sits, If it’s done properly to the rite thickness, not too thin, not too thick, it will wear extremely well, but it’s a tricky business with some shifty operators, Buyer Beware! Sorry about hi-jacking the subject, let’s get on with it.

[Jonesy :-)]

Geez makzy your excused but I'm worried about my memory, I was in doing cam work only a month ago

Lambs yeah whoever it was that didnt prep your frame probably isn't in business anymore. I've got a powder coated frame that has seen over 20 years and tens of thousands of kms of service and holding up better than the paint that came before