350 "trials" project milestone
Posted: Fri Jan 03, 2020 8:27 pm
So my "old" 2007 350 bullet suffered catastrophic engine failure last Spring with a snapped valve.
It's done about 80-90k miles but a bit like Triggers broom. This was one of our hosts performance tuned heads.
After a whole lot of elbow grease.
Local light engineering guy re-cut the valve seat for me and fitted a new valve guide.
there was however more failure to come. It turns out the drive shaft was also loose in the flywheel and had ovalled it. i got a recon needle roller crank and new mains but when I came to fit it, it wouldn't go down. Turns out the timing shaft had been ground to 1" instead of 25mm. That had to go back.
I got lucky and found a NOS Meteor piston for it and got it all reassembled.
I decided to totally dismantle it and rebuild with a view to making a trials-style machine which I intend to enter some Classic trials on. I'm doing it in the spirit of these trials, so an old bike cobbled together on the cheap in a home workshop, using as many original parts and homecooked solutions as possible. It's not meant to be a pristine show bike, it's meant for riding places and getting mucky.
Frame stripped and repainted with alkyd machine enamel.
Second hand half width hub off ebay.
Engine rebuilt and in.
Home fabricated sump guard.
Used trials exhaust from our hosts.
Home fabricated brake pedal.
Flipped and swapped pillion peg mounts (these may not stand up to testing but it's a starting point, worth a try, cost me nothing but time).
Custom loom made with multicore cable and run through an old tea-caddy mounted on the opposite side with a dinky little battery in it. ZX6r reg/rec.
Also made a relay control unit to route the AC lighting using a C90 switchgear.
An old set of renthal desert bars from the shed. GPZ500 clutch levers for brake and clutch. LED bulbs everywhere but the headlight.
Relocated speedo to rear wheel.
I'm using plastic mudguards. Alloy look good but these are tough like tonka toys.
Working on the tank, needs a few more coats of plastikote quick dry enamel.
And the milestone?
First start:
https://youtu.be/mvoGCZ4kfKY
Well that works. The relay controlled AC lighting also works, as does the charging system.
Still some finishing up and tuning to do but it looks like the project is a go! The aim is to take it to the Dragon Rally next month for a proper shakedown.
It's done about 80-90k miles but a bit like Triggers broom. This was one of our hosts performance tuned heads.
After a whole lot of elbow grease.
Local light engineering guy re-cut the valve seat for me and fitted a new valve guide.
there was however more failure to come. It turns out the drive shaft was also loose in the flywheel and had ovalled it. i got a recon needle roller crank and new mains but when I came to fit it, it wouldn't go down. Turns out the timing shaft had been ground to 1" instead of 25mm. That had to go back.
I got lucky and found a NOS Meteor piston for it and got it all reassembled.
I decided to totally dismantle it and rebuild with a view to making a trials-style machine which I intend to enter some Classic trials on. I'm doing it in the spirit of these trials, so an old bike cobbled together on the cheap in a home workshop, using as many original parts and homecooked solutions as possible. It's not meant to be a pristine show bike, it's meant for riding places and getting mucky.
Frame stripped and repainted with alkyd machine enamel.
Second hand half width hub off ebay.
Engine rebuilt and in.
Home fabricated sump guard.
Used trials exhaust from our hosts.
Home fabricated brake pedal.
Flipped and swapped pillion peg mounts (these may not stand up to testing but it's a starting point, worth a try, cost me nothing but time).
Custom loom made with multicore cable and run through an old tea-caddy mounted on the opposite side with a dinky little battery in it. ZX6r reg/rec.
Also made a relay control unit to route the AC lighting using a C90 switchgear.
An old set of renthal desert bars from the shed. GPZ500 clutch levers for brake and clutch. LED bulbs everywhere but the headlight.
Relocated speedo to rear wheel.
I'm using plastic mudguards. Alloy look good but these are tough like tonka toys.
Working on the tank, needs a few more coats of plastikote quick dry enamel.
And the milestone?
First start:
https://youtu.be/mvoGCZ4kfKY
Well that works. The relay controlled AC lighting also works, as does the charging system.
Still some finishing up and tuning to do but it looks like the project is a go! The aim is to take it to the Dragon Rally next month for a proper shakedown.