My first ever bike build!!

[Airwolfie]

- Mount headlight properly DONE!!!
- Find replacement line for clutch DONE!!!
- finish off foot pegs DONE!!
- mount indicators DONE!!
- mount coils DONE!!!
- mount tacho and speedo DONE!!
- mount Boyer ignition DONE!!!
- add fake oil tank for housing electrics DONE!!
- add key starter DONE!!!
- add hi/lo light switch DONE!!!
- add kill switch DONE!!!
- add neutral light DONE!!!
- add spark leadsDONE!!!
-Install Boyer power boxDONE!!!
-Install one way valve on breather DONE!!!
-Bleed clutchDONE!!!
- plug excess petcock holesDONE!!!
- add petcockDONE!!!
- install fuel lineDONE!!!
- add filter podsDONE!!!
-clean and line gas tankDONE!!!
- fabricate rear fenderDONE!!!
- mount rear fenderDONE!!!
- mount rear lightDONE!!!
- add hornDONE!!!
- replace tyresDONE!!!
- fab steering stopDONE!!!
- make spacers for calipers/rotorsDONE!!!
- paint gas tankDONE!!!
- add chainDONE!!!
- Find replacement brake line for front brakeDONE!!!
- recon front caliperDONE!!!
-Bleed brakesDONE!!!
- sort out exhaustsDONE!!!
- mount rear brake switchDONE!!!
- wire entire bikeDONE THE ENGINE!!!
- add oilDONE!!!
- mount front fenderlDONE!!!
- add fuelDONE!!!
- run engineDONE!!!
- paint fenders
- mount number plateDONE!!!
- tune engine
- get MOT!!

Got my number plate today, so I stuck it on.

I also started on some prep and paint on the front mudguard

 

[Airwolfie]

So I decided to remove the basket and check my shift selector by the star. The equidistance to the left and right was out by 1mm! Could this havebeen part of the problem not being able to shift the gears?

I did check if the star runs through all the gears, and it does! Fingers crossed when I get the plates, all will be good!!

Might even get them tomorrow! First I got to soak them in oil though..........

 

[peanut]

while you have the basket off Id check the entire clutch system really carefully for any signs of rubbing or binding.

Im sure you have already checked everything but just in case ,Have you checked that you have both ball bearings fitted incl the one in the worm drive and they are the correct size . Also check the start resting position of the worm lever arm which should be perpendicular to the line of the cable.

My feeling is that your plates were sticking due to being stuck together for months rather than being warped. They would have to be very warped to jam in the clutch basket fingers.

My betting is if you were to fit it all back together it would work ok due to the plates being seperated when you took it all apart

Am I right in thinking that the problem was the clutch not releasing rather than not changing gear

 

[Airwolfie]

I checked it all mate! I have the single rod, so only one BB in there!

Worm lever arm is good and where it should be.

Plates were warped, you could see there were 3 or 4 burnt spots on them, an indication of warpage says my motorbike mechanic friend!

The clutch was releasing, but I could not get the sweet spot. It would either bite fully and not disengage completely, or not bite fully, slipping to the point where I can let go of the clutch and hold the front brake and the engine would carry on going, but I could disengage the clutch completely.

Got new plates and discs coming, along with the bolt upgrade, the ones with the hex rather than the Phillips heads.

 

[peanut]

I checked it all mate! I have the single rod, so only one BB in there!

.

no there are two ball bearings


the symptoms you describe sound like friction problems to me

 

[Airwolfie]

Yes OK, two, one in the worm gear, and one after the mushroom shaped thingy.

Everything moves freely as it should. Let's see if these plates will solve the problem!

 

[Airwolfie]

- Mount headlight properly DONE!!!
- Find replacement line for clutch DONE!!!
- finish off foot pegs DONE!!
- mount indicators DONE!!
- mount coils DONE!!!
- mount tacho and speedo DONE!!
- mount Boyer ignition DONE!!!
- add fake oil tank for housing electrics DONE!!
- add key starter DONE!!!
- add hi/lo light switch DONE!!!
- add kill switch DONE!!!
- add neutral light DONE!!!
- add spark leadsDONE!!!
-Install Boyer power boxDONE!!!
-Install one way valve on breather DONE!!!
-Bleed clutchDONE!!!
- plug excess petcock holesDONE!!!
- add petcockDONE!!!
- install fuel lineDONE!!!
- add filter podsDONE!!!
-clean and line gas tankDONE!!!
- fabricate rear fenderDONE!!!
- mount rear fenderDONE!!!
- mount rear lightDONE!!!
- add hornDONE!!!
- replace tyresDONE!!!
- fab steering stopDONE!!!
- make spacers for calipers/rotorsDONE!!!
- paint gas tankDONE!!!
- add chainDONE!!!
- Find replacement brake line for front brakeDONE!!!
- recon front caliperDONE!!!
-Bleed brakesDONE!!!
- sort out exhaustsDONE!!!
- mount rear brake switchDONE!!!
- wire entire bikeDONE THE ENGINE AND FRONT AND REAR LIGHTS!!!
- add oilDONE!!!
- mount front fenderlDONE!!!
- add fuelDONE!!!
- run engineDONE!!!
- paint fendersDONE!!!
- mount number plateDONE!!!
- tune engine
- get MOT!!

Finished painting and mounted the front mudguard this weekend. I also started on the wiring and managed to get the front and rear lights wired up! Getting close!

 

[I am Carbon]

You know that alot of these engines have the 2 piece pushrod and they have 2 balls 3 with the wormgear. The 1 piece rod is a upgrade.
Did You get the clutch put back in?
the mugguard looks good.

ruadadyet?

 

[scabber]

I agree with carbon nice job on the mudguard. Looks factory and goes great with the look of the bike.

 

[peanut]

How did you get on with the clutch ?? can you now get all the gears ?

Hey snap with the boxes !

 

[Airwolfie]

You know that alot of these engines have the 2 piece pushrod and they have 2 balls 3 with the wormgear. The 1 piece rod is a upgrade.
Did You get the clutch put back in?
the mugguard looks good.

ruadadyet?

Yeah, mine had the 2 piece, but I ditched it even before the start of my build!
Got the clutch pack in, SO FAR, in the shed, I can shift through all the gears, I haven't tried with it running yet as I can't get er out the shed on my own!

Not a dad yet brother!!

I agree with carbon nice job on the mudguard. Looks factory and goes great with the look of the bike.

Thanks Scabber and Carbon!

How did you get on with the clutch ?? can you now get all the gears ?

Hey snap with the boxes !

Yeah got the clutch in and I can shift through all the gears, haven't tried with it running yet.

Hehe yeah those boxes! They do come in handy don't they!

 

[dilbone]

Airwolfie I'm starving for an update here!!!!

What's going on?

 

[fredintoon]

Airwolfie I'm starving for an update here!!!!
What's going on?

Hi dilbone,
what with those ruadadyet? posts, maybe he's out shopping for a pram?

 

[peanut]

I reckon he must be knee deep in nappies about now

 

[dilbone]

Hi dilbone,
what with those ruadadyet? posts, maybe he's out shopping for a pram?

or a side car...better yet!!!!! lol

I reckon he must be knee deep in nappies about now

haha, yep...probably walking around like a zombie with no sleep and can't figure out how the clutch got wrapped up in a diaper...

I hope all is well Airwolfie!!!!!!

 

[I am Carbon]

Yes he is a Dad of a baby Girl born on the 24th
He is very busy taking care of his wife and baby.
I might be awhile before he will be a regular again

 

[peanut]

thanks for the update.

Congratulations AW

when we gonna see a picture of your baby girl on the bike then ?

 

[Airwolfie]

Hey guys! Just a quick pop in! No updates as I have been up to my knees in nappies and clothes and sleepless nights winding baby and lulling her back to sleep!

Was a very eventful weekend! Started on the friday night, the missus having contractions, she then got induced on Saturday afternoon as nothing was kicking off. By Sunday morning, still nothing, so they decided to intervene, broke the water, she then started to dilate, but stopped at 6cm. Then the doc decided to do an emergency c-section. It was a big shock to us, as we never even thought that could happen. Little Hannah was pulled out the sunroof at 5:05am Sunday morning! What a momentous day!

I now have mom and baby to look after, takes a LOT out of you! Almost like being a single dad with a newborn! The missus can't and is not allowed to do just about anything, she struggles to hold the little one, let alone feed and change her diapers!

No pics of her on the bike yet, but it will happen!!

Hopefully I will get the bike done in a couple of weeks, I'll keep you posted!!

 

[fredintoon]

Hi Airwolfie and congratulations,
BTDT, including the homebirth that morphed into an emergency C-section.
As you may have already discovered, happiness is 3 hours of sleep.

 

[peanut]

good on ya AW .

Good to hear that all is well .

Best get your head down for a few Zzzzzzzzz whilst you can mate