Rad & Fab

Cleaned and sprayed the radiator which was in pretty good condition. just a lot of corrosion. So the cooling system is ready to go all the pipes and expansion tank are connected up.

The original rear footrest hangers also included the exhaust hanger on the left hand side. I am not refitting these so instead I fabricated a hanger bracket for the exhaust  from an aluminium off cut which is 3mm thick and very inexpensive and easy to polish!

Detour

Lined up part of the next project - spotted a cheap Yamaha RD250 engine for sale online and bought it. Its a 1975 twin model and needs a lot of work as you can see from the pics below. It came with the original 28mm Mikuni carbs and 2 ignition coils which seem to have been butchered at some point.

I am thinking along two different directions for this project, [1] transplant the engine into a Yamaha FZR250/400 chassis and [2] cafe racer.

Stainless Line

Thought i would post up some images of the rear brake setup with the new braided HEL line.

Exhausted

This evening I fitted the expansion chamber after spraying it black yesterday with heat resistant paint. A few weeks ago I did a bit of a de-coke on it along with the end-can. I heated it up to apply the paint and it was still smoking but nothing to the way it was before the de-coke.

 

Rounded top

In an effort to complete the assembly of the right hand hanger I made a master cylinder plunger/piston from a plain bolt. I cut the head off and used a dremel to round the top. I applied red rubber grease to the contact point on the master cylinder. This is a stop gap until I happen across the original plunger.

Usually 1 but sometimes 2

was planning on getting a lot done today, rear wheel fitted with brake system and realised the wheel bearings I got are the the wrong size. But I cannot tap the originals out so I started with removing the rear wheel sprocket carrier and of course the bolts were seized and not 1 but 2 broke off. With them removed I cannot remove this part of the wheel ?

Mislaid

After fitting the left hand hanger and gear change mechanism I moved on to the right hand hanger to start assembling and realised I misplaced the master cylinder plunger. I remember cleaning it and painting it and I vaguely remember putting it "somewhere safe" so that i'll "find it when I need it". Spent about 45 minutes searching for it.
I also need to find a home for two alternator earth cables, in the workshop manual it says to bolt them to the engine and shows a small image of the location but it does not correspond to this engine?

Spaghetti

Still working on the electrics and the various bolt on bits and pieces that accompany the task.