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Bike of my dreams

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Vincent This post is not being displayed because the poster is banned. Unhide this post / all posts.

bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 08:49 - 14 Oct 2015    Post subject: Reply with quote

So the carbs from E-bay turned up.

https://i491.photobucket.com/albums/rr279/bladeblaster/12141082_10153182941204013_1468178551592066076_o_zpsqz9sgagl.jpg

Only to find that the butterflies are fairly seized, but not sure why. So I get to stripping them down.

Then I find that 2 idle mixture screws are missing and the 2 that are there are both knackered. Managed to get one out, the other one has no chance.

So I go to plan D

I only really need the one body, so I can take the body I need and swap it with the broken body on the other set.

So I start breaking down the bank, most of the screws holding the back together are seized or already rounded off, but hopefully in here somewhere is one good set of carbs.



https://i491.photobucket.com/albums/rr279/bladeblaster/12113447_10153183531559013_595131859415084979_o_zpslhl0cir9.jpg


Took the bank to work and drilled off the screw heads on the pillar drill, separated them, only to find that the body I need is the one with the seized butterfly Evil or Very Mad

So 8 carb bodies, and no 1 good full set Brick Wall

So plan E a full set of A1/A2 carbs came up on ebay so I have bought those. Should arrive today, they had better be good.
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andym
World Chat Champion



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PostPosted: 09:14 - 14 Oct 2015    Post subject: Reply with quote

I'm glad I didn't go to all this trouble with my GPz project.... but then I'm also slightly disappointed Confused

I haven't really had the need to strip carbs down to individual pods, so I'll admit I haven't got a clue what I'm talking about here.... but aren't they all the same when EVERYTHING is stripped from them? Or at least in pairs anyway?

Also with the screws on my carbs, they were big enough to get a set of needle nosed mole grips on there to crack them, had to replace all the bottom ones because they were all rounded etc, the top ones I didn't even bother putting much force in to the screwdriver before going for the mole grips again
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 11:18 - 14 Oct 2015    Post subject: Reply with quote

andym wrote:

I haven't really had the need to strip carbs down to individual pods, so I'll admit I haven't got a clue what I'm talking about here.... but aren't they all the same when EVERYTHING is stripped from them? Or at least in pairs anyway?


Well they probably are, BUT removing the butterfly assembly is a no go, at least on the outside ones as far as I can see. But TBH I didn't really investigate too much as I didn't to completely knacker it. However once I know the new set is good, and I have nothing to loose, I will have a go. Thumbs Up
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Undinist
Nearly there...



Joined: 08 Oct 2013
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PostPosted: 12:39 - 14 Oct 2015    Post subject: Reply with quote

Thank you OP, you've saved me thousands of pounds and a shedload of grief - your posts have cured me of the notion that I could one day restore a bike. I don't have the skills or patience and my 'workshop' is unbolting parts in the street and cleaning them in the kitchen.
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Current bike: K1100RS. Previous: CD200, GSX250, GT550, VFR750, K100LT, K1100LT, R1100GS, R1150GS, ZZR1100, Hayabusa, RSV Mille, MV F4 750S, R1, ZX-10, KTM Adventure 950S
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andym
World Chat Champion



Joined: 16 Nov 2010
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PostPosted: 12:53 - 14 Oct 2015    Post subject: Reply with quote

Sorry OP, couple of pictures to show that you don't need a "workshop"

Undinist wrote:
Thank you OP, you've saved me thousands of pounds and a shedload of grief - your posts have cured me of the notion that I could one day restore a bike. I don't have the skills or patience and my 'workshop' is unbolting parts in the street and cleaning them in the kitchen.


That's no excuse, I had a driveway and a first floor flat:

GPz being rebuilt on the driveway:
https://img.photobucket.com/albums/v320/andy36586/GPz750/enginefitted.jpg

ZXR engine being rebuilt in the livingroom:
https://img.photobucket.com/albums/v320/andy36586/Engine-rebuilt-4_zpsf10ab7ad.jpg
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Undinist
Nearly there...



Joined: 08 Oct 2013
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PostPosted: 13:15 - 14 Oct 2015    Post subject: Reply with quote

That's impressive. But I don't have a driveway. I suppose I could designate a corner of the bathroom as a motorcycle mess. Thinking
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Current bike: K1100RS. Previous: CD200, GSX250, GT550, VFR750, K100LT, K1100LT, R1100GS, R1150GS, ZZR1100, Hayabusa, RSV Mille, MV F4 750S, R1, ZX-10, KTM Adventure 950S
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 14:31 - 14 Oct 2015    Post subject: Reply with quote

you def don't need a workshop, but it sure does help.

Patience, well that's definitely something you do need.
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Vincent This post is not being displayed because the poster is banned. Unhide this post / all posts.

bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 08:49 - 15 Oct 2015    Post subject: Reply with quote

Vincent wrote:
Those butterfly valves...........I was reading about a tool to help get them off the other day so don't abandon hope. I'll have a look for it.................

Do you have close up pics?

If they're screws...and you've rounded them off.......you're not the first Wink


The actual butterfly, as in the metal disc inside the carb is held on with 2 screws, that bit shouldn't be a problem.

The shaft that its screwed to, is blank on one end, and on the other end is riveted / peened over so it would have to be ground off that end. It may press out from the other end I am not sure. I need to have a look at an exploded diagram, and hopefully that will shed some light.

It is slowly freeing up with regular applications of penetrating fluid, I may put it back through the ultrasonic bath over the weekend.

The new carbs turned up yesterday, and they appear to be spot on. So really I am only working on the sticking one now out of interest, and if I get it fully operational I can sell it. If it ends up in the bin now, its no great loss. Thumbs Up
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 14:11 - 20 Oct 2015    Post subject: Reply with quote

Time for a Carb Saga update.

Repeated application of penetrating fluid did free up the stuck butterfly quite well in the end.

The new carbs looked really good when they arrived, so good I was considering bolting them straight on. However I didn't and I am glad I didn't, the insides we covered in rusty coloured fuel residue. Worse than that all 4 idle adjuster screws were missing their o-ring seals. The ends of teh adjusters were black as hell, must have run as lean as an anorexic bacon sandwich.

So new set stripped & cleaned, I had new idle adjuster seals that I had already bought so that wasn't a problem. So once all cleaned out, time to re-assemble.

Bottom end:-

Vernier set to 17mm to check float heights

https://i491.photobucket.com/albums/rr279/bladeblaster/12112217_10153196568834013_4964418979589696153_n_zpsqzasasar.jpg

Floats & Shut Off Valve in, first checking that the rubber pointy end is in good nick, and the spring on top of the valve is strong & moves freely.

https://i491.photobucket.com/albums/rr279/bladeblaster/12108232_10153196568419013_3674561498513765901_n_zpst7ubzzpe.jpg

Check float height, this one was low as you can see by the gap between the top of the float and the bottom of the vernier body.

https://i491.photobucket.com/albums/rr279/bladeblaster/11222547_10153196568829013_2153848052827561133_o_zpsiqqamwka.jpg

So adjust by bending the small metal tab that the float hangs off, one way or another. Low float means the tab needs bending towards the float. Its a trial and error amount, not an exact science, just keep re-fitting & checking until you get this. The float needs to be sat just on top of the valve without compressing the spring on top of the valve, when you take the measurement.

https://i491.photobucket.com/albums/rr279/bladeblaster/11148220_10153196568839013_4810299778051141949_n_zpsejz01h1m.jpg

Now back in with the various jets:-

Needle Jet

https://i491.photobucket.com/albums/rr279/bladeblaster/11167656_10153196568814013_1465843608683305132_n_zpsq4wuxamc.jpg

Emulsion Tube

https://i491.photobucket.com/albums/rr279/bladeblaster/12115559_10153196568809013_4023030134465796180_n_zpsbuezajnc.jpg

Main Jet

https://i491.photobucket.com/albums/rr279/bladeblaster/12107261_10153196569024013_1117731871199962690_n_zpsykmi5gse.jpg

Pilot Jet

https://i491.photobucket.com/albums/rr279/bladeblaster/1470113_10153196569014013_1377343245997196888_n_zpsidd59egw.jpg

Pilot Adjustment Screw, properly assembled with o-ring seal.

https://i491.photobucket.com/albums/rr279/bladeblaster/12118957_10153196569019013_5542635927046347486_n_zpss1arpti0.jpg

New seal in the float bowl.

https://i491.photobucket.com/albums/rr279/bladeblaster/12095216_10153196569009013_2536180955551177679_o_zpsqnwjwinw.jpg

Now for the top end.

Little bit of Rubber Grease to help the diaphragms seat properly.

https://i491.photobucket.com/albums/rr279/bladeblaster/887479_10153196568459013_9044056090785655878_o_zps8sbz5fsx.jpg

Diaphragm & slide back in, and top face greased.

https://i491.photobucket.com/albums/rr279/bladeblaster/12113291_10153196568439013_2167408889080786081_o_zpsbyvyqd13.jpg

Main Needle In.

https://i491.photobucket.com/albums/rr279/bladeblaster/12095106_10153196568424013_4499037246402542073_o%201_zpsvqe0uhfh.jpg

Spring seat & Spring in, taking care not to black the vacuum port with the spring seat. It has to sit with the legs either side of the hole, if its positioned with a leg blocking the hole, it knackers up the vacuum, and it will never fuel properly.

https://i491.photobucket.com/albums/rr279/bladeblaster/12095278_10153196568454013_19244337403836481_o_zpsyqshbkrr.jpg

Then tops on, and all back together, with nice new cap heads & spring washers.

https://i491.photobucket.com/albums/rr279/bladeblaster/11223925_10153196562389013_1989842155309956333_o_zpszcwbcmaw.jpg
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 16:01 - 29 Dec 2015    Post subject: Reply with quote

well after a long delay for various reasons, the rebuilt carbs are finally in, tank on, and after a bit of persuasion she fired up!!

No oil leak, no fuel leak, and no water leak. All in all very happy.

https://i491.photobucket.com/albums/rr279/bladeblaster/12402102_10153311598649013_5731123952539850697_o_zpsr37i2jtm.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/12401901_10153311597259013_1073222878668105580_o_zpsz4mnutxq.jpg

Next on the shopping list, a new rear shock.
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Vincent This post is not being displayed because the poster is banned. Unhide this post / all posts.

bladeblaster
Trackday Trickster



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PostPosted: 19:58 - 31 Dec 2015    Post subject: Reply with quote

More progress today.

Rear suspension stripped out.

https://i491.photobucket.com/albums/rr279/bladeblaster/10381991_10153316150029013_2743669320893333527_n_zpsr7qepvpb.jpg

Excessive play in the linkages. Dogbones cleaned up nice though. Before and after:-

https://i491.photobucket.com/albums/rr279/bladeblaster/1915194_10153316150369013_7868732115725447861_n_zpsobzd8d3r.jpg

New, bearings, bushes and seals required though.

Front fairings back on as well.

https://i491.photobucket.com/albums/rr279/bladeblaster/1272823_10153316232574013_2329591955678865927_o_zpsgsijqisx.jpg
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Duffman
Renault 5 Driver



Joined: 08 Nov 2015
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PostPosted: 11:14 - 22 Jan 2016    Post subject: Reply with quote

Awesome thread, just joined the motorbike world and BCF and this is the best thread ive found.

i do feel inadequate though Confused
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 13:01 - 22 Jan 2016    Post subject: Reply with quote

Duffman-MT wrote:
Awesome thread, just joined the motorbike world and BCF and this is the best thread ive found.

i do feel inadequate though Confused


Thanks.

Many years of trial and error, driven by necessity, and lack of funds to pay someone else to do it.

I am still learning every time I work on a bike.
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chickenstrip
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PostPosted: 13:06 - 22 Jan 2016    Post subject: Re: Bike of my dreams Reply with quote

bladeblaster wrote:
probably so cheap because it was advertised as needing a new starter clutch which is a big job. Easily a grand to be done in a bike shop.


So what of this? Was the seller wrong?
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bladeblaster
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PostPosted: 17:03 - 25 Jan 2016    Post subject: Re: Bike of my dreams Reply with quote

chickenstrip wrote:
bladeblaster wrote:
probably so cheap because it was advertised as needing a new starter clutch which is a big job. Easily a grand to be done in a bike shop.


So what of this? Was the seller wrong?


No he was right. Although it was working fine for a time, it is now playing up again.

It's iffy, but speaking to people the can stick when stood for a while. It def worked ok, after it had been moved around in a van a couple of times. Now its been stood idle for a few months seems to be acting up again. I am going to wing it at the moment, and just see how it goes.

At some point I am going to get another motor for it anyway, so will be a straight swap.

I want to strip and rebuild this motor with a BBK.

I have much plans for this bike.
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bladeblaster
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PostPosted: 15:01 - 01 Mar 2016    Post subject: Reply with quote

Out with the old rusty linkage bearings.

https://i491.photobucket.com/albums/rr279/bladeblaster/new%20bearing%204_zpslnz4h0ig.jpg

And in with the new

https://i491.photobucket.com/albums/rr279/bladeblaster/new%20bearing%203_zpsy1xgeopf.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/new%20bearing%202_zpsouy0m2aj.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/new%20bearing%201_zpshkaybvdu.jpg[img][/img]
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thosoneill
Renault 5 Driver



Joined: 07 Mar 2013
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PostPosted: 11:21 - 03 Mar 2016    Post subject: Reply with quote

Thanks mate for a decent thread - it's amazing the amount of wear and tear a motorcycle is subjected to - fantastic you have the ability to fault find and repair - I doubt any dealer could have done better - well done that man - fancy changing my belt and rollers Wink
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bladeblaster
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PostPosted: 09:33 - 14 Mar 2016    Post subject: Reply with quote

A very frustrating weekend on the GPZ Evil or Very Mad

The good news, the rear shock is in.

https://i491.photobucket.com/albums/rr279/bladeblaster/12814712_10153455965669013_5885533068047598212_n_zpsdtisqvx5.jpg

The bad news, I thought I had the circlips for the tie rods, but I didn't so I couldn't finish fitting it, needs circlips fitting then everything torqued up.

More good news, the front lines are fitted.

https://i491.photobucket.com/albums/rr279/bladeblaster/12186233_10153455997439013_5213086437354038805_o_zpsqtnpvuyr.jpg

The bad news, the reservoir screws were so chewed up they are unusable, so need new ones before I re-fill the system. So couldn't finish that job either.

To top it off tried starting her again, and come to the conclusion that the starter clutch really is totally shot, so the engine is going to have to come out after all. I know I knew but after the false hope it gave me early on, it feels like a bit of a kick in the balls.

1 step forward and 2 steps back, definitely a weekend where you question the sanity of owning a 30+ year old bike, and wanting to take a match to it Crying or Very sad
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Just_James
Could Be A Chat Bot



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PostPosted: 00:55 - 15 Mar 2016    Post subject: Reply with quote

Bit of a shitter with the starter clutch but it will be worth it in the end... easy for me to say as I'm not the one that has to do it Mr. Green

Really liking the detailed thread on this though, keep it up Thumbs Up
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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 11:44 - 21 Mar 2016    Post subject: Reply with quote

A much more positive day on the bike yesterday.

Suspension linkage all back together with circlips, back wheel back in, rear caliper back on with new braided hose, front hoses bled.

She is now more complete than she has been in months. so next weekend I can start stripping off everything ready for the engine to come out .............. Rolling Eyes

https://i491.photobucket.com/albums/rr279/bladeblaster/aaa_zps4zdsejbf.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/aaaa_zpsxkyfjirv.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/aa_zpszwwfnmbb.jpg
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 17:07 - 31 Mar 2016    Post subject: Reply with quote

Everything stripped off ready to drop the engine out. Must resist the temptation to start buying new shiney bits that I don;t need like billet rad brackets, etc etc.

https://i491.photobucket.com/albums/rr279/bladeblaster/aaa_zpslpw2ndl3.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/aaaaa_zpsq49jit7c.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/a_zps2caetleg.jpg
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 12:02 - 08 May 2016    Post subject: Reply with quote

well after more delays, mostly due to traveling for work, the engine is finally out.


Now I need a free weekend to get stuck in to the gearbox.

https://i491.photobucket.com/albums/rr279/bladeblaster/13138882_10153594721389013_4204543917392536561_n_zpskhpjoenw.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/13177154_10153594721314013_7912014622369357687_n_zpsrn5idpi9.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/13179370_10153594721509013_9005478300331543586_n_zpszi7lltz7.jpg
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