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  1. #61
    Registered User MVLUV's Avatar
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    Using 1.6mm solder and the same method. Also worth mentioning that there was no play in the connecting rods.

    Scouring through other threads shows it is not unusual for a stock engine to have this kind of squish clearance.
    Last edited by MVLUV; 02-08-17 at 06:45 PM.

  2. #62
    whaddayatalkinabeet brasher's Avatar
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    Yep fair enough. Go the thinner gasket and it will be a 98 octane only jigger obviously.

    Done a few 125/250 engines with 0.8 and all is well on Pump fuel providing you jet it well.

  3. #63
    Registered User MVLUV's Avatar
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    Thanks for the input as. Have already decided to get some dyno time when done. Changing too many things to expect the current jetting to be spot on. Also I don't trust my plug chopping skills.

  4. #64
    Non Compos Mentos Gammaboy's Avatar
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    Measure squish using plasticine.
    Definitely worth getting it to the 0.9mm squish region.
    "Where can we get hold of a Vincent Black Shadow?" "Whats that?" "A fantastic bike," I said. "The new model is something like two thousand cubic inches, developing two hundred brake-horsepower at four thousand revolutions per minute on a magnesium frame with two styrofoam seats and a total curb weight of exactly two hundred pounds."

  5. #65
    whaddayatalkinabeet brasher's Avatar
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    Yeah dyno will be worth your while. The bikes I've done there is so much info in the dirt bike community regarding builds and jetting that you can pick up a setting that's 9/10ths the way there and fine tune on the "private racetrack" aka local industrial estate lol.

    Only bike I had issues with was a mates 03 cr250 that due to a few too many clipped rings ended up at 280cc and we managed to torch that piston due to just plain misjudging how much fuel that mongrel needed. Once it was sweet that bike was scary fast. You could only kick it with mx boots on or steel caps. The recoil was deadly.

  6. #66
    Registered User MVLUV's Avatar
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    1mm gaskets arrived. They are spot on, after installing re-did squish measurements and measured 0.85 - 0.9 across both cylinders. Also ordered new oil lines and fuel lines. Seems the factory were 'economical' with oil line tubing as you could play a tune on the lines.

    In the pic below you can see the difference in squish. Top one is the original 1.4mm base gasket at 1.3mm squish.
    Bottom one is 1mm base gasket with 0.9 squish.
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  7. #67
    Registered User MVLUV's Avatar
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    Engine in with new oil feed lines and fuel lines. After comparing new to old lines, confirmed that they were well overdue. New um 'distinctive' silicone coolant lines in.
    Will set power valve pulley cables a little further down the track as I inadvertently rotated the actuator motor out of the home position so setting cables now will be pointless.
    Fortunately when ignition is turned on valves go through an open cycle and back to home position.
    One other issue I noticed was the left carb slide didn't want to seat all that quickly when the throttle was shut off.
    Turns out guide and slide were gummed up with tacky 2T oil. All good now with a thorough degrease.
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  8. #68
    Registered User MVLUV's Avatar
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    Also stumbled on my old scale collection that I boxed away after the 2011 floods. Some were unsalvagable but the kids are enjoying playing with those ones anyway so all is not lost.
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  9. #69
    Registered User MVLUV's Avatar
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    Have dug into the brakes. On the couple of dodgy laps around the block I did while it was running they did work albeit wooden and not a lot of bite. With that in mind I thought they probably won't be too bad. New pistons and seals too be sure.

    This is what all three calipers and both master cylinders looked like. Not one of the dust seals was still in its groove at some point.
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  10. #70
    Registered User MVLUV's Avatar
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    After about 2 hrs of cleaning and dremel work only small amounts of corrosion are still evident.
    New pistons, seals and liberal amounts of rubber grease in the seal grooves will hopefully arrest further corrosion.
    First pic is the front master cylinder under the dust boot.
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  11. #71
    Jak Sie Masz! trent from punchy's Avatar
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    looking good.

    I went through a similar rebuild of the brakes and they feel great now.
    www.markpakula.com
    2017 Subaru Impreza Hatch - for the grind
    2015 Cervelo S2 - for the fitness
    2005 Honda Accord Euro - for the wife
    1991 CBR250RR - for the fun

  12. #72
    Registered User MVLUV's Avatar
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    Got half a day to spend on this a few days ago and managed to tick some items off the list.
    Tyres mounted balanced and on bike. (Learned of another bike shop to not go to).
    Chain cut and fitted.
    Rear sets and shifter linkage on.
    Exhausts mounted.
    Calipers mounted.
    Both master cylinders rebuilt and mounted.
    Radiator fins straightened mounted and plumbed in.
    Powdercoated bits re-fitted, (top triple, sidestand, clutch perch and headlight bracket).
    Clutch cable connected.

    Also turned ignition on and power valve actuator rotated back to home position. This was after I accidentally rotated it tightening front slave pulley. Now it's in position to set up the cables.Click image for larger version. 

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    I don't normally like to whine however the last two bike shops I have had dealings with were very dissapointing. It must be difficult to run a business nowadays, I know I don't have the drive for it, but if I did I would make workmanship and customer service on top of the list to constantly improve. / Rant.
    Last edited by MVLUV; 15-09-17 at 09:58 AM.

  13. #73
    Non Compos Mentos Gammaboy's Avatar
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    I fit and balance my own bike tyres these days... Chipped paint?
    "Where can we get hold of a Vincent Black Shadow?" "Whats that?" "A fantastic bike," I said. "The new model is something like two thousand cubic inches, developing two hundred brake-horsepower at four thousand revolutions per minute on a magnesium frame with two styrofoam seats and a total curb weight of exactly two hundred pounds."

  14. #74
    Registered User MVLUV's Avatar
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    Managed to get the tyres off but new tyres were putting up a good fight with levers. So rather than chip the powdercoat took them to a shop and 2 hrs turned into 2 days and rear wheel weight fell off in the shop, no one had noticed. Asked for it to be rebalanced. Fell off again next day after I had fitted wheels.
    No biggie I can balance at home but am sick of either getting the crusty old disinterested disgruntled type or the young flatbrim illiterate dickhead.

  15. #75
    Registered User MVLUV's Avatar
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    Quote Originally Posted by Gammaboy View Post
    I fit and balance my own bike tyres these days... Chipped paint?
    Do you have a jig or just levers and bad language?

    Rebalanced and mounted rear wheel. This is a handy add on to the rear paddock stand.
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  16. #76
    Registered User MVLUV's Avatar
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    Used a spare front resorvoir and bracket I had and cut down the original hose.
    Bracket bolts to the inside of the subframe mount.
    Vaccum bleeding line took all of 5 mins then a couple of pump and bleeds for good measure resulted in a firm lever.
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  17. #77
    Registered User MVLUV's Avatar
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    Set up the power valve pulley tension. Set up slack per the manual then used the 'grey wire' test.
    This is a handy option that involves grounding a loose grey wire in the loom which indexes the power valve actuator to the mid point.
    The bc pulley wheels are supplied with a locating pin rather than aligning marks on the OEM ones.
    Once the wheels were in the mid position I simply adjusted the cables to suit so the pin aligned through the wheels and into the bc bracket.
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  18. #78
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    This is coming along really well. Are there any big ticket items left before it's up and running? Do the fairings need any work?

  19. #79
    Non Compos Mentos Gammaboy's Avatar
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    Quote Originally Posted by MVLUV View Post
    Do you have a jig or just levers and bad language?

    Rebalanced and mounted rear wheel. This is a handy add on to the rear paddock stand.
    Levers.
    I like the balancing jig - source?
    "Where can we get hold of a Vincent Black Shadow?" "Whats that?" "A fantastic bike," I said. "The new model is something like two thousand cubic inches, developing two hundred brake-horsepower at four thousand revolutions per minute on a magnesium frame with two styrofoam seats and a total curb weight of exactly two hundred pounds."

  20. #80
    Registered User MVLUV's Avatar
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    Quote Originally Posted by fnlow View Post
    This is coming along really well. Are there any big ticket items left before it's up and running? Do the fairings need any work?
    Rear shock is on its way. Waiting on a couple of bits and pieces to arrive (rad bleed screw, double banjo as wemoto sent 10x1.25 insread of 10x1.00).Tail piece is in good condition, front fairing is still boxed up.
    Will rego with original front fairing and do paint after run in.
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  21. #81
    Registered User MVLUV's Avatar
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    Quote Originally Posted by Gammaboy View Post
    Levers.
    I like the balancing jig - source?
    La corsa jig balancer. Ordered through Honda stealership a couple of years ago for a stand I already had.
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  22. #82
    Registered User MVLUV's Avatar
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    As mentioned in a previous post I'm waiting on a radiator bleed screw. I broke this while unscrewing to obviously bleed air out of the radiator. Being plastic and probably gone through several hundred heat cycles, was overdue for replacement.
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  23. #83
    Registered User MVLUV's Avatar
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    Tyga subframe has zero mounting tabs or threads bar exhaust and seat mount, so cut off a piece of alu angle for a rear brake line mount. Would rest on rear spring as shown in second pic. First pic is final position.
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  24. #84
    Registered User MVLUV's Avatar
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    Cleaned old oil and accumulated dust off air box and pipercross air filter in. Replaced carb to air box flanges and clamps as old ones were a little sad.
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  25. #85
    Registered User MVLUV's Avatar
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    Got this running on Friday after a failed attempt Thursday. Fuel bowls overflowed from stuck float valves. Worst offender in pics.
    Started on 30 to 1 premix with oil lines disconnected and oil pump wedged wide open. Pump didn't take long to prime as I had left the lines off with oil in the tank to let gravity do its job.
    Was surprised how little smoke was generated as I was pretty generous on oil during assembly. Can only put it down to less smoke from modern oil?
    Will probably farm out the jetting and initial tune as a. I don't really know what I am doing and b. I only get time to play with this once the family is asleep.
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  26. #86
    whaddayatalkinabeet brasher's Avatar
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    30:1 should smoke like a chimney, but that's fine. A lot depends on the oil. Castrol smokes like crazy but maxima doesn't. I just buy the cheapest synthetic I can on special.

    I hate starting them for the first time, they always get that crazy runaway revs at first and you think you have an air leak or something but just have to trust your work.

    Good stuff, coming along nicely.

  27. #87
    Registered User MVLUV's Avatar
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    I agree was very nervous, double checked everything. Kept thinking something not right with such little smoke but was on premix so had to be getting oil. Tripple checked my maths with ratio 17ml oil for 500ml fuel.

  28. #88
    whaddayatalkinabeet brasher's Avatar
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    whoah that's way too hard.

    Castrol 2T app. Input litres of fuel and desired ratio and it spits out the oil amount

  29. #89
    Registered User MVLUV's Avatar
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    Thanks didn't know it existed.

  30. #90
    Registered User MVLUV's Avatar
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    Shock has arrived. This is a work of art and the preload adjustment is so smooth and easy to adjust.

    Also ordered a battery indicator. Rather than have a large digital indicator or checking with a meter, a quick glance at this led should indicate battery level.
    Last edited by MVLUV; 17-10-17 at 06:23 PM.

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