winter project No: 581

[Jonesy]

Just the top end,
Carbys are also getting a slight mod to make tuning easier.

[XSIIE]

Hey Jonesy,

Did you paint the complete engine or just the top end?

XSIIE

[AussiXS11G]

nice job painting the engine - looks great
B

[Jonesy]

The airbox and inlet manifolds are fitted up and a new K & N air filter is on the way.



And the carbies have had the best part of a full day of being stripped, cleaned and inspected.
you know you've had a good day in the shed when you come in and the missus tells you smell like petrol and "I'll never get those clean" plus theres 3 messages for you  (the sheds a long way from the house)

[Jonesy]

maybe a quick homemade clamp made from the front end of an old cruiser ,,1/2 a chep pallet and a front wieght of a small tractor should do the trick   

Aha great minds think alike,
I had a bit of a twist to your method.
I possy'd it up in place on a pallet against the tractor weight and then gently nudged the 4th bowl with the cruiser towbar

[steptoe]

so what number fuel bowl will you lever against when you hit number four

maybe a quick homemade clamp made from the front end of an old cruiser ,,1/2 a chep pallet and a front wieght of a small tractor should do the trick

it,s coming along nicely from the pics tho

[Jonesy]

started on the carbys today, I see a challenge ahead, first diaphram/slide assembly I went to ull out was stuck in place after 14 or so years of just sitting, went to attack from the bowl side and I had to get very persuasive  with "gentle heat" from a paint stripper gun and heavy tapping with a plastic screw driver handle to get the bowl, off until finally I had to lever against the adjacent bowl with a hammer handle.

My favourite
thick tarry petrol evaporation residue



and  white powdery alloy corrosion with spiderwebs.

[Jonesy]

Errol
It'll be interesting to get the next member who does a chain replacement to compare the old with the new.
I know the chain thats in service on #581  now has very little adjustment left.
Might look into a longer travel adjustor if the replacement (new) chain proves to be longer from the get go.

[Eveready1100]

Hey Jonesey, Getting back to this.......................

Interesting info there Jeff....the numbers I've got will make the new chain approx 2.1mm longer than the old one so shouldnt be tight like the 650 chain

I'm thinking again

Does this mean that if we fit a new aftermarket camchain at that length, we're losing a lot of movement from our adjuster as the slack would be taken up on the intitial adjustment?

Does this mean I've been doing my dough replacing them when the tensioner has run out of travel, if the chain is longer to start with??

I think I'll pay more attention next time I fit a new one, and check used travel after installation!!!

[Eveready1100]

Sorry, mate. It was hidden in the thread - "Drivetrain Breakdown" CLOINK







It did look ok to me till I pulled it out and cleaned it up like in the pics. That's when I saw the wear in the splines. I was really surprised to see them so bad, because, like I said, the diff flange was really good.

[Jonesy]

Errol I didnt remove the shaft but I cleaned up better than what the pic shows and had a close up inspection with my Aldi inspection camera and I'm satisfied the splines are healthy. I had a look but couldnt find your post covering the inspection you did on yours, all I found was a pic from it that you put in Bryan's "Dry splines"

[Eveready1100]

The lack of wear is surprising as there is some evidence that the bike might have done some time on the race track? well bevelled footpegs and lock wired drain plugs.........hmm

Might've been done in preparation for its appearance at Amaroo park in 78, eh?

You did pull out the driveshaft to clean the splines up. right?

That's what my input socket? for the final drive looked like on mine. Just slightly polished but with no wear. But my driveshaft splines were shot.

[Jonesy]

Well I got a bit side tracked and instead of working on the fuel side of things I ended up fitting the spin on filter and adaptor that I got off Christian. filter changes will be a piece of cake from here on and as discussed in other posts I pre filled the filter to help get the oil where its needed quicker on initial start up......still a bit down the track yet.


I also took the opportunity while the bike was un rideable and up on the bench to check out the final drive shaft and other splines that have been discussed recently. glad to say that mine came up quite well
the pictures are a bit sh#t but you get the idea.
Input spline to the final drive has the slightest of wear marks on the drive side of the spline teeth

Not a great photo but in real life the splines profiles have virtually no wear. did I mention tight arse rebuild? its also the lazy re-build....couldnt be bothered pulling it right out so just cleaned it up in situ.


The lack of wear is surprising as there is some evidence that the bike might have done some time on the race track? well bevelled footpegs and lock wired drain plugs.........hmm

[BrettS]

Great work on the project Jonesy. Looking forward to seeing it together, Winter is comming to an end 

[Jonesy]

A little more progress today.
Green coils are mounted.
Head is on with cams timed, dots all lined up....that took a while.



Now for some fueling around

carby's and fuel taps are next for examination and renovation