[Marko_SJ]

Hi guys, I'd just like to start a thread on this so I can document for anyone who's interested what I've done, not only this, my questions were filling up the "Motorbikes" chat thread.

I have a habit of forgetting whats broken, whats ordered etc...

In all its busted arse glory when I first brought it home.



Its own spot in the shed, the faithful 200 on the right has scored some goodies lately too



The first thing I did was put a kit through the carbies, as it didn't run. I found the carbies were a bigger bore off a later model, without the necessary jetting adjustements done. Float level was way wrong, needle seat was gone. So I changed thejets out for what I thought would be close.



This was the good 'clean' floatbowl. Yum!



All back together, breathers look yuck but they are clear.



I took it for a spin straight after and it went like a scalded cat! I got right up the road till it went lean and died, after pushing it back (it was a long walk), I found that the fuel tap was nearly 100% clogged, and seemed to be "leaning out" and dieing, so it'd go awesome for a few minutes and just stop dead. Hence why I think the PO adjusted the float height right up

Anyway. During that I found that the cooling system was knackerd. Check out the colour and some of the previous owners handiwork



No hoseclamps? thats fine just go to Thinkwater!

[Marko_SJ]

After the cooling system was fixed with a new rad and bled properly I was able to do for another test ride. I found the clutch was fucked and so was the gearbox.

I forgot to take photos of this so will update later, probably when I have it all apart, which may not be soon as I'm finding it hard to find a 'box.

The list is for now:

New gearbox/ second gear

new clutch

top end rebuild

head tube bearings (i think they only need a bit of pre-load added.)

rebuild forks

re-install oil injection

Also thanks to Ball, who's answered dumb question after dumb question.

[Gromet]

Love my 2 strokes.... I have a NSR150 under the house and a GT185 up stairs on display.

[Marko_SJ]

Yeah I've seen them in the motorbikes thread. To tell the truth I probably woulda prefered a GT550 to this, but I'll take what I can get!

[Gromet]

Yeh I would love to have 3 expansion chambers all twisted around the engine. ..

[Marko_SJ]

Gromet wrote:

Yeh I would love to have 3 expansion chambers all twisted around the engine. ..

Just the sound of the triple is what does it for me...

Anyway, fingers crossed I hear back from Showandgo wreckers about a gearbox cassette.

Mark

[Marko_SJ]

Sourced a box.

[greenzook89]

[Gromet]

Marko_SJ wrote:

Sourced a box.

HAPPY VALENTINES DAY!!! hope she isn't loose.

[Marko_SJ]

^^^ got some box on valentines day, but had to pay for it...

[Marko_SJ]

Gearbox (parts, turns out they didn't have the whole lot) turned up

Started the strip down of the engine.





1st cylinder, more yuckiness:



Second:

[Marko_SJ]

Somebody obviously couldn't wait for a gasket or was too tight to buy one. Note gear oil drain bolt too. Multi grips FTL?





Clutch looks newer than the rest ? You can also see why the kickstart didn't return



more chunky goodness:



and a poor lit picture of the cylinder:

[Marko_SJ]

Another photo dump

Gedit?









One side PVs out.



Cleaned up, ball reckons they don't look farked, which is good cause two sets cost as much as a sierra





Its spreading



So need to de coke other cylinder, remove crank then clean the cases up.

[Marko_SJ]

So pulled into the gearbox the other day.



Found some sorry looking shift forks, they measure up at the minimum spec thickness but look shit. Could be bent too. My spare gearbox looks healthier, so might use the gears off the new gearbox with the shafts of the old one, and buy brand new shift forks and should hopefully make a nice gearbox... Also contemplating a new output shaft.








Will probably try to track down a new shift linkage, because the old one is sloppy, potentially causing the damage to the geabox in the first place.

[Marko_SJ]

Also, this clutch basket, anyone reckons its done and need replacing?



The part where the "fingers" on the clutch disk pack sit has slight wear on it as well as what you can see on the inside.

[gvzookdriver]

you love taking blurry photos. or do i just need glasses lol

sorry i can't help with any of this. But looks like a very in-depth build

[Marko_SJ]

gvzookdriver wrote:

you love taking blurry photos. or do i just need glasses lol

sorry i can't help with any of this. But looks like a very in-depth build

Thanks for looking at the thread, Peter isn't it?

I'm in a catch 22 with a lot of the photos. Take it too far away, and it doesn't get details of the wear on small parts, put it too close (like I have done in a few of the pics, my mistake) and the camera wont focus.

I think I need a new camera. Its 5 megapixels which is less than most phones now, also the flash isn't working which isnt too good for a lot of these things.

Gunna take the gear clusters apart next.
My mate literally by chance found a video of the PO riding it lol.

[Marko_SJ]

Made one gearbox out of two, decided I needed new shift forks because the second handies look a bit second hand (less than mine though).

Got in touch with "Blue City Motorcycles" in SA, hopefully they can get me the bits I need including a flywheel puller...

I suppose I need to order a gasket kit and crank stuff soon.

Edit: All bits to finish engine on their way. Today was an expensive day.

[Marko_SJ]

Well I'm missing lots of stuff in between, such as some powdercoating and a full suspension conversion, but its looking more like a bike again.



Dealing with a couple of leaks:

Clutch cover (have replaced gasket twice now, it might need the surface sanded flat, or just some silifella.

Exhaust manifolds (didn't have correct gaskets)

Hoping to have it ready by the 20th for round 1 Hidden Valley ride day. I've taken it for a quick lap, geeze its quick.

[rustyzook]

That looks a lot better than the first pic mate! I don't know anything about bikes, but I like it

[Marko_SJ]

Cheers rusty.

The light at the end of the tunnel seems close now!

[shep]

Who did your crank? I want to get my TZ going but am unsure who to give the bottom end to

[Marko_SJ]

shep wrote:

Who did your crank? I want to get my TZ going but am unsure who to give the bottom end to

Graham Selwood from CRS. He is at Dundee these days but I don't think he wants anymore work. (In fact, the last time I saw him I asked if he wanted any of Ball's stuff and his response was "he can do them himself")

I might be able to dig up a contact who does MX cranks but no idea if he does multi cylinders.

[coneykid]

Nice suzuki. Biggest regret I have is selling my rgv. Had a 92. Was awesome fun. Highly recommend a good steering dampener. There a 250 widowmaker.

[Marko_SJ]

coneykid wrote:

Nice suzuki. Biggest regret I have is selling my rgv. Had a 92. Was awesome fun. Highly recommend a good steering dampener. There a 250 widowmaker.

Thanks mate.

Just doing the last of the paint prep work now on the track fairings!

I'll shake it down first then put it back on the road. Did you try running more rear sag or changing fork mounting position to do away with headshakes?

Mark

[Marko_SJ]

Track bike project is finished. I was not able to get a good paint job unfortunately so Chinah fairings it is.

road race season is over so I dont have a chance to shake it down. A mate has offered to buy this off me for a price I am happy with so it should change hands soon. I want to get rid of it before I ride it, otherwise I wont be able to part with it, to make room for my next bike.

[Marko_SJ]

Gone.

Now resides in my mate's living room being worked on in comfort and out of the weather.

I hated seeing my hard work being undone because I had nowhere to work on it or store it properly.