It's been a while since the last post, but this is the final part. It's been three and a half weeks since I started the downpipes, and it has been absolute torture not having transport (and the weather we've had has been perfect ugh). Anyway, the last post I had cleaned the head and block up ready for paint. Here's what has happened since. Get ready for a wall of text followed by a tonne of pictures.
So I got the head and block painted, and it looked dapper - I couldn't wait to get it back on the bike with some stainless pipes. I waited for the paint to dry overnight and got them back on fairly easily. The pistons were a bit of a chew on to get in the cylinder but with some patience and perseverance I got there. Things were going well. I got the cams back on and started to time it up. That's when I realised things were going too well. I just couldn't get the timing right, I was a tooth out on the exhaust and 2 out on the intake. Back off with the cam holders (such a chew on), adjust, back together. A tooth out on the intake, exhaust was fine. Back off again, when I dropped 2 dowels and a bolt. I found a dowel and the bolt, but it left the dowel lying in the bike somewhere. I was adament it didn't drop down the cam chain tunnel but had to be safe, so decided to drop the sump - nothing in there, and now I have to wait for a new gasket as well as a new dowel, the dowel being on back order.
So I got the head and block painted, and it looked dapper - I couldn't wait to get it back on the bike with some stainless pipes. I waited for the paint to dry overnight and got them back on fairly easily. The pistons were a bit of a chew on to get in the cylinder but with some patience and perseverance I got there. Things were going well. I got the cams back on and started to time it up. That's when I realised things were going too well. I just couldn't get the timing right, I was a tooth out on the exhaust and 2 out on the intake. Back off with the cam holders (such a chew on), adjust, back together. A tooth out on the intake, exhaust was fine. Back off again, when I dropped 2 dowels and a bolt. I found a dowel and the bolt, but it left the dowel lying in the bike somewhere. I was adament it didn't drop down the cam chain tunnel but had to be safe, so decided to drop the sump - nothing in there, and now I have to wait for a new gasket as well as a new dowel, the dowel being on back order.
So I decided to leave it there. I mean, there was nothing I could do but wait for the parts. I just wasn't prepared to refit the cam holders without this dowel. I must have spent 2 hours looking for it on the bike, but just couldn't find it. Anyway, 10 days later and the dowel arrives - Saturday. I go straight out to the garage and decide I'm not quitting until the valve cover is installed. Great, cams on, let's try this timing. 1 tooth out on each. How the?! Oh, I'm sick of this, but I take it all to bits again and careful adjust the sprockets by one tooth each. Back together and bingo! Yes, we're rocking. Valve cover on and feeling very positive for Monday to finish it.
So, today is Monday. Early start in the garage, fitting the carbs and all the pipes, the airbox, battery and so on. Things are going well. Nothing really to write about, it was a textbook assembly, everything going to plan.
Next, new downpipes on - a bit fiddly, would have been easy with 2 sets of hands but I managed, very carefully tightening the nuts (after copper greasing them and using dome nuts). Back box on, and we're about ready to test this. I quick prayer to God for its success, and here we go. Hmmmm, carbs are empty of petrol. Just need to keep trying. Battery flat, sugar! Connect a jump start battery and keep trying, it's coming, it's coming! And yes! We have lift off.
I had a little smoke from the front - at first I thought it was not sealed, but sure it's just oils etc burning off as it didn't last long. Bike sounds good, except for a bit chugging noise - I've since found out it's the clutch and perhaps a carb balance will help, but nothing to worry about tonight. Quickly service the chain ready for a test ride - front and back wheels moving as freely as I can expect. Let's go - all sounds good and looks like the job is done.
I just need to refit my lower fairing (need new nuts and bolts to do so) as well as giving it a good wash. It's been a bit of a ball ache from start to finish, but most of that has been the stress of waiting for parts, especially the dowel. It's given me masses of experience and confidence ready for my KZ project, and so glad I did it - I wouldn't like to think what it might have cost for the garage to do all this work.
So it's been fully serviced, had pretty much a top end rebuild, and is now sporting lovely shiny downpipes as well as a new looking head/block. I'm buzzing. Oh, and you'll never guess what dropped off the bike when I wheeled it out the garage - yes, the missing dowel, unbelievable.
Oh, and three weeks of perfect weather. You'll never guess what the forecast is for the rest of the week. Absolutely typical.
So, today is Monday. Early start in the garage, fitting the carbs and all the pipes, the airbox, battery and so on. Things are going well. Nothing really to write about, it was a textbook assembly, everything going to plan.
Next, new downpipes on - a bit fiddly, would have been easy with 2 sets of hands but I managed, very carefully tightening the nuts (after copper greasing them and using dome nuts). Back box on, and we're about ready to test this. I quick prayer to God for its success, and here we go. Hmmmm, carbs are empty of petrol. Just need to keep trying. Battery flat, sugar! Connect a jump start battery and keep trying, it's coming, it's coming! And yes! We have lift off.
I had a little smoke from the front - at first I thought it was not sealed, but sure it's just oils etc burning off as it didn't last long. Bike sounds good, except for a bit chugging noise - I've since found out it's the clutch and perhaps a carb balance will help, but nothing to worry about tonight. Quickly service the chain ready for a test ride - front and back wheels moving as freely as I can expect. Let's go - all sounds good and looks like the job is done.
I just need to refit my lower fairing (need new nuts and bolts to do so) as well as giving it a good wash. It's been a bit of a ball ache from start to finish, but most of that has been the stress of waiting for parts, especially the dowel. It's given me masses of experience and confidence ready for my KZ project, and so glad I did it - I wouldn't like to think what it might have cost for the garage to do all this work.
So it's been fully serviced, had pretty much a top end rebuild, and is now sporting lovely shiny downpipes as well as a new looking head/block. I'm buzzing. Oh, and you'll never guess what dropped off the bike when I wheeled it out the garage - yes, the missing dowel, unbelievable.
Oh, and three weeks of perfect weather. You'll never guess what the forecast is for the rest of the week. Absolutely typical.