Fuel tap parts

Gearbox parts

Fuel Tap

Left side bolted up

Oil Pump

Received my refurbed oil pump this week, it looks "new" got it fitted and piped up last night. the main feed pipe is Ariete material and the feeds to the carbs are Tygon.

Tank Liner Removal

Today I started with the tank liner removal and preperation for the new liner to go in.

I used an offcut of a wheel tube and a small offcut of aluminium plate to blank off the fuel tap hole.

Then the Caswell liner removal solution went in to disolve the old liner, I guess the solution is MEK or cellulose, it seems to have done the job. Before emptying the chemical out I threw in 20 wood screws to loosen up any stubborn debris, after a good shake a small pinhole appeared and was literally covered with paint so a little bit more of soldering to be done. 

Before that happens Ill rinse out the tank with soapy water to expell the chemical vapours. Thats for tomorrow though.

Plugging Holes

As with all old metal tanks and crap modern petrol therr comes a time whrn the holy tank needs to be repaired.

I stripped off the paint to reveal the holes around the fuel tap area and plugged them with flux core solder.

Next up is to remove the old liner and replace with caswell tank liner.

Chain Roller

 Fitted a new chain roller on a 6mm aluminium plate and fixed to the rear of the rearset mounting bolts.

Clutch Cable Holder

Swingarm bobbins

Made a set of swingarm bobbins for the new stand hooks

Carbs again

Finally got around to fitting the reed block spacers, these are 5mm spacers and came supplied with gaskets.

Next up is to rebuild the carbs to standard settings and fit!

1/10/20 update.

Carbs built but fitting to the airbox is torture!

update 03/10/20 Airbox Mod.

update 04/10/20 mod complete

Clutch Pushrod

Properly fitted the side case with the clutch pushrod actuator engaged. The sprocket fitted with an 8mm spacer behind clears the actuator.

Chain Run

Fitted a new 38T rear sprocket and fitted an old chain to calculate the length of new chain needed, but ran into a few issues previously overlooked or missed. 

I really need an 8mm offset front sprocket which will line up with the rear chain on a standard un-shaved carrier and also clear the inner face of the chain tunnel of the swingarm. I was hoping a 4mm offset would work but the chain is too close to the swingarm.

Running the 8mm offset or any offset for that matter creates 2 problems, (a.) the chain will hit or run too close to the exhaust and (b.) the chain and sprocket will be too close or hit the clutch pushrod actuator on the inside of the side case.

Problem (a.) can be over come with a secondary chain roller ?????

Problem (b.) ?????

Microns

Been tipping along with various little jobs, got the clutch fitted finally. 250LC Microns are now fitted. I had a set of short springs for this so I made some W clips to make up the shortfall of the springs and coated them in red high temp paint.

Timing and Heads

Finished the ignition system today by setting the timing and fitting the flywheel followed by fitting and torquing the heads.

The gap betwen the pickup and the ramp on the flywheel is 0.016 and the timing set to 1.89mm BTDC.

The heads were fitted and the newely coated red head bolts torqued to 19nm.

Clutch Basket

Carb to Airbox

Im using a standard YPVS F2 airbox but an issue has arisen and I see a problem ahead connecting the carbs to the airbox rubbers.

The carb to cylinder inlet rubbers dont line up with the airbox rubbers, hopefully there is enough play in the rubbers to make everything connect.

I need to setup the carbs after the ultrasonic clean and rebuild the had recently.

Front Brakes Fitted

Small update while waiting for parts, I fitted a different Aprilia front caliper as I didnt feel the red didnt suit the dull gold of the rear. I made up a new Goodridge braided line with stainless banjos.

Got the reservoir relocated for a better pipe connection to the master cylinder.

Clutch Pressure Plate