The Fun Begins

[Kato]

Now before I say anything more I lay the blame for this firmly at the feet of EONAN who sparked the idea for a few mods with his gorgeous 900. thx Mate:twak:


So not that many days ago my bike looked like this.....
http://i142.photobucket.com/albums/r94/kato--/Duc.jpg

Not that bad realy (well I thought so) BUT several days after that it looked like this.

http://i142.photobucket.com/albums/r94/kato--/oldframe1.jpg
http://i142.photobucket.com/albums/r94/kato--/OldEng1.jpg

so far so good yesterday I picked up this bit, Oh B*&%$£KS now I have to remember where it all fits..:on:
http://i142.photobucket.com/albums/r94/kato--/frame1.jpg
http://i142.photobucket.com/albums/r94/kato--/frame2.jpg

[stef]

i dont think the engine will work as it is.
i think you probably wont get much compression.

good luck though.

[Kato]

Don't know what you mean Stef just took those two paperweights out of them cylinder things, could'nt see them properly hidden in there.

[jerry]

what a messy garage!!!!!!!hope it all fits back together...watch out for the mice.

jerry

[retskcid]

what a messy garage!!!!!!!hope it all fits back together...watch out for the mice.

jerry

haha, yeah, I'm sure there's a motorcycle in here somewhere!

Rich

ps lookin forward to following the rebuild

[Nickj]

If you drill lots of holes in the paperweights they're lighter and can go up and down (or backwards and forwards) much faster.... All the fast two strokes I had usually ended up with this as a modification LOL

[Albie]

Your stupid taking your bike apart. Do you hear me STUPID.:rolleyes:

Dont do it again and hurry up and put it back again before your mother finds out.

Good one mate I hope it all goes well :thumbsup: :thumbsup:

[gremlin]

what a messy garage!!!!!!!hope it all fits back together...watch out for the mice.

jerry

i would love my garage to be that tidy :chuckle: :chuckle:

[Albie]

You want to see the state of mine at the moment. Well it has been worse but its still messy .

[Shandy]

Nice...............this is where the fun begins!!!

Trust me you only need the following to get it all working again,

Haynes Manual
Workshop Manual
Parts Catalogue off the web with exploded parts views

Between all of these you can figure out what goes where.....

.........if all that fails just have a few beers :cool:

Good Luck,

Cheers,

Shandy

[Kato]

Nice...............this is where the fun begins!!!



.........if all that fails just have a few beers :cool:

Good Luck,

Cheers,

Shandy


Think thats what got me into this mess in the first place.....:banghead:

[giler]

So what are the plans for the final look?

[JerryXt]

..garage? Remind me again?

[Kato]

So what are the plans for the final look?

Hmmmm Plans now theres a thing:idea: ...So far the only original bit going to be used is the front half of the frame, rear has been chopped and modified to use the later seat lock, also some of the bracing has been modified or removed 888 style, bottom end of the motor is finished (last night) waiting on the the swing arm to be made and need to get the cyl heads on the motor so as I can put the frame on and start building it up, I know I don't need to do it this way round but its easier.

[giler]

Swingarm to be made, sounds interesting!

[Albie]

Hmmmm Plans now theres a thing:idea: ...So far the only original bit going to be used is the front half of the frame, rear has been chopped and modified to use the later seat lock, also some of the bracing has been modified or removed 888 style, bottom end of the motor is finished (last night) waiting on the the swing arm to be made and need to get the cyl heads on the motor so as I can put the frame on and start building it up, I know I don't need to do it this way round but its easier.


Its much easier to build up from the floor with engine then frame on top and rear suspension then forks and finally wheels.

In my opinion which aint worth tuppence.

[Kato]

The Motor started out pretty shabby: I wanted a really over the top motor but most of the parts for that are still with Chris at CA Cycleworks so I decided to build up my spare motor and use all the bits I have collected over the past months, I can then take my time to make the original motor very very special when all the parts turn up until then......

http://i142.photobucket.com/albums/r94/kato--/Engine1.jpg

So a bit of spit & polish was needed:
http://i142.photobucket.com/albums/r94/kato--/NewPistons.jpg
http://i142.photobucket.com/albums/r94/kato--/Engnew1.jpg
http://i142.photobucket.com/albums/r94/kato--/Engnew2.jpg
http://i142.photobucket.com/albums/r94/kato--/Engnew4.jpg
http://i142.photobucket.com/albums/r94/kato--/Engnew3.jpg

Fitted with 94mm pistons, alloy flywheel, Bucci slipper cluch with a Barnett basket and Barnett clutch plates, STM crank breather.

Tonight I'll set the squish and fit the heads.

[CK & AK]

shiney bits..... grrrrrrr :cool:

Coming on nicely mate. When are you aiming to have it on the road?
AK was in the garage last night doing some shimming to some heads.......as well as making things for the rear wheel of ours.......

[stef]

very shiny indeed.
how did you get the grub out ? steam ?

[Pedro]

Looking good but please tell me you're gonna lose the purple banjo bolts on the oil feed lines...!

[Half Man Half Mole]

Very purdy :thumbsup:

Keep the pics coming.

Mike

[Kato]

Looking good but please tell me you're gonna lose the purple banjo bolts on the oil feed lines...!

Sorry Ped they were the only ones I had that fitted, that side cover was from an i.e motor and when I drilled and taped the case I picked up the wrong tap, need to order some less garish one's :)

[Albie]

Hows it looking then Kato ??

[stef]

yes, i let me ask again : how did you get it so shiny ? did you steam it ?

[Kato]

yes, i let me ask again : how did you get it so shiny ? did you steam it ?

Jizer a stiff brush and a hose pipe.....followed by getting banished from the house for smelling like an "oil slick" so returned to the garage to discharge lots of cfc's from a paint tin onto the freshley laundered motor...:idea:

[Kato]

Right was getting a bit frustrated waiting for my new swingarm to rock up so fitted the old one for the time being, also used the original triple clamps for now although that was not the plan but I can't find / make up my mind what I want anyway here's a few more pic's of my weekends toil..........
http://i142.photobucket.com/albums/r94/kato--/shock.jpg
http://i142.photobucket.com/albums/r94/kato--/brake1.jpg
http://i142.photobucket.com/albums/r94/kato--/brake2.jpg
http://i142.photobucket.com/albums/r94/kato--/frontfork1.jpg
http://i142.photobucket.com/albums/r94/kato--/ff.jpg

[stef]

so what do those brake and clutch levers transform into ?
they are transformers, right ?

[Albie]

They are very nice levers indeed

[Kato]

Radial levers are by ISR very trick and infinately adjustable

http://www.isr-brakes.se/

[Lowsider]

Please for god's sake replace the oil pressure sensor it looks old and knackered and lets the engine down.

[adds666]

If only i had the expertise, time, patience and money to do this to my 620. Had her a while now and done about 7 thousand more than the 9k i bought her with and is really looking old and knackered. Only 53 plate!

[gary tompkins]

They are very nice levers indeed

Albie - I think the words you are looking for is "pure sex"

Looking very nice Kato :cool:

[Kato]

Finally we are getting somewhere, in a mad rush to get up to Arrow Mill I had to neglect work for a couple of days and finish the paint on the tank & seat, then put the rear suspension back in as my new swing arm is not here yet so I had to use the old one with original wheel, the 999 one will not yet fit properly, so the bike got its first ride and a very nervous few miles over to AK's it was, until it got stowed into the van I kept waiting for bits to fall off and wondering how many things I'd forgotton to check.....anyway wow how happy was I with a string of 2nd's and 3rd overall for a bike thats not even finished thanks to all who voted for her....

http://i142.photobucket.com/albums/r94/kato--/intake.jpg
http://i142.photobucket.com/albums/r94/kato--/naked.jpg
http://i142.photobucket.com/albums/r94/kato--/Tankfinished.jpg
http://i142.photobucket.com/albums/r94/kato--/Bum2.jpg
http://i142.photobucket.com/albums/r94/kato--/Bum.jpg
http://i142.photobucket.com/albums/r94/kato--/front-1.jpg
http://i142.photobucket.com/albums/r94/kato--/Side.jpg

[gary tompkins]

That pearl red & black paintwork is just fantastic :thumbsup:

[Mand]

That pearl red & black paintwork is just fantastic :thumbsup:

I second that. :cool:

[Albie]

I had a vote for yours too. I must say me old mucker I love the idea of the indicators built in to the seat unit. Now that was some thinking. ;) ;) :D

It looks brill and was worried when it turned up in AK's van. Tried to dismiss it :on: :on:

Well done for bringing her up and am dead upset you never got a trophy but then I never thought I would.I thought Nonnie had it all sewn up.

[alreadyinuse]

me likey 999 wheels

[Kato]

That pearl red & black paintwork is just fantastic :thumbsup:

I second that. :cool:

Thanks GT / Mand....glad you liked it took me a lot of shouting and $£%^&* to get it right 3 coats of jet black the 4 coats of luna silver then mask the stripe 6 coats of candy black then mask up again 4 coats of candy red remove all masking another 2 coats of red then 6 coats of clear, that lot probably puts back the weight I saved with the aluminium tank and carbon seat unit...:drunk:

[Kato]

I had a vote for yours too. I must say me old mucker I love the idea of the indicators built in to the seat unit. Now that was some thinking. ;) ;) :D

It looks brill and was worried when it turned up in AK's van. Tried to dismiss it :on: :on:

Well done for bringing her up and am dead upset you never got a trophy but then I never thought I would.I thought Nonnie had it all sewn up.

Thx Mate, it was always goning to be yours as mine is only half finished and would'nt even start, prob having a protest at the rain as it fired up first time when it got home.....

[Albie]

Thx Mate, it was always goning to be yours as mine is only half finished and would'nt even start, prob having a protest at the rain as it fired up first time when it got home.....

Its good of you to say so but I never held my breath as competitions I never win unless I am the only entry. I honestly thought Nonnie would wrap up all.

[Kato]

Well I've had an industrious afternoon, my MBP heads have arrived and I could'nt wait any longer to fit them along with the FCR's on Malossi short intakes....

Heads now have oil feed to the cam's
http://i142.photobucket.com/albums/r94/kato--/OilFeed.jpg

http://i142.photobucket.com/albums/r94/kato--/carbies.jpg

http://i142.photobucket.com/albums/r94/kato--/carbies2.jpg

[Plum]

That look sweet kato...when can i drop my ratty old 98 dog to you........if you could sort that it really would destroy the myth 'You cant polish a turd'

[Snips]

I second that. :cool:



I third it.

Just catching up with this thread, sorry.

Awesome paint job. When I read the dedication & skill it took, I was even more impressed.

It looks 'the biz' <-- showing my age

[adam15]

Extremely nice bike, I bet those FCR's will make a difference ;)
Hope mine looks that good when its finished :)

[Mark Taylor]

Wow, what an awesome engine (and bike) how much power? Where do the extra oil feeds to the heads come from? How did you turn the carbs round? Why short intakes-more low,mid or top end power? WOW!