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    Hydraulic Clutch

    Hey Guys, just fitted a Honda CBR1000 Clutch slave cylinder to my casing - all gone well, with correct allignment etc I'm using the Honda Clutch pushrod, as it has the rounded end for the slave cylinder. I need some views on how much play I should leave with the cylinder at rest, I was think...
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    Regulator Rectifier - can a later Yam model be used?

    Guys, thought I would come to the guru's for a definitive answer on this one! My combined Reg/Rec is testing faulty on the diodes, so I thought I would ask on our UK facebook Forum if anyone new of a replacement that would work, that did not cost near a £100 Been advised that later model...
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    Converting earlier Stator to TCI

    Quick question Guys, Looking to install the later Brush Holder - seems easiest way and reasonably easy to drill and shape. However this does leave one of the wires slightly short - before I start tugging on wires, has anyone had success pulling slack past the windings on the brush wires? My...
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    Gonzo Project. Pick up wires: only 2 used?

    Guys, I'm finally at the "getting a spark" stage of my build. I've got a suspect original TCI Box that I could not get to function on my test bed so I've picked up a couple of GN250 boxes and just sorting out the temp wiring set up this weekend. Am I right that only the Black "Ground" and Orange...
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    Ignition Questions

    Hi Guys, as you know got an XS650 SE (basket Case). engine is now rebuilt ready to be fitted in the frame, Carbs all fully rebuilt and ready to go. Ignition with the bike is standard TDI. I wanted to bench test the ignition connecting the pickups, TDI box and connecting in a battery, with a...
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    Camchain Tensioner Issue

    Afternoon Guys, Finally got round to my top end rebuild after numerous delays - Only one problem, my final task was to put the cap on my Cam Chain Tensioner (type D) all parts are correct as per INXS'S post in the tech section On tightening the cap as its moving towards sealing, its meeting the...
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    Permatex Copper Gasket Dressing

    Guys, ive read the excellent top end rebuild thread (a few times now) and from this and other posts its seems like a very good idea to use Permatex Copper Spray on the Head Gasket and to put a very small bead of not setting Gasket sealer around the outside edge of both sides of the base gasket...
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    Setting the Camchain Tensioner

    Hi Guys, Nearly ready for top end put together, last bit is ensuring I know initial setting position of Camchain adjuster. Mines a Type D (after I pieced all the bits together) All the manuals, books forums say to use the adjuster rod being flush with the end of adjuster screw as rough guide...
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    Stator Fix/Adapt

    Hey Guys, just running through my parts to see what i need down the road to get this Basket case back to life. Ignition and charging plays on my mind, here is what i have: A bike that was originally Electronic (its not CDI, i know) ignition. From the bike: Transistor box, Correct Coil...
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    Skimming Cylinder Head surface to Remove/reduce pitting

    Guys a very straightforward question, which i cant find a straightforward answer too. I have some pitting on the alloy sealing surface of my cylinder head - its not major, but i can feel my fingernail against the steel part of the combustion camber (only just). I believe that skimming by 0.2mm...
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    Clutch Pushrod 1 or 2 Piece?

    Hey Guys, work commitments, means my rebuild has slowed down! just about to install the Clutch and have been thinking about the pushrod. Long before the internet i rebuilt an XS engine and I think it had a 1 piece job. Problem with that bike (which seems to be common): When cold the clutch...
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    How to hold crankshaft to remove Primary drive pinion nut

    Hi Guys, found damage to small end of my conrod yesterday - dropped i assume by previous owner, or one of the many while, the engine has been in dismantled state! ( I cant believe i had not spotted this earlier, I think i focused too much on the bearing conditions) So, biting the bullett, I...
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    Endless Camchain Fitting

    Hey Guys, hope your all well and getting out on the bikes? Been pointed out to me that if your fitting an endless camchain, you need to grind back either the pivot rivet on one side or the brace/roller. did do a search, but the link to the external website on this is missing really want an...
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    Details of Crankcase nuts and bolts needed

    Hey Guys, Planned to do a dry fit of Crankcase halves today to make sure i had every seal, Nut and bolt to hand - it seems I have bolts, nuts and washers missing! All studs are correctly in place, what i need to know is the following: 1. Using the numbering scheme, which are the 6 nuts that...
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    Sold / Found / Inactive - Locating Circlip for Output Shaft Large bearing wanted in the UK

    Guys, unsurprisingly, I cant seem to find these for sale anywhere, but really need 1 to let me progress with getting the crankcases closed up on my basket case build. Please let me know if you have one you would be willing to sell in the UK Thanks Barrie
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    Crankcase oil jets - I have too many!

    Hey Guys, Started the engine rebuild sorted out a good Gear Selector drum and bearings and moved onto checking oilways (keep in mind this engine came to me in boxs, with cases stripped and painted, bores honed and new piston kits hmm!) Anyway i noticed that WD was coming out of an unusual...
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    Gear Selector Forks Drum and Pins

    Guys, The XS650 Engine book is on its way, but this is the rebuild part, i knew would be a pain: The selector drum came removed from the crankcase, but with the forks attached and the pin/s shown as below. The pin looks nothing like in the Haynes manual (2 piece with a roller) is this a later...
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    Stage 1 of engine rebuild

    Morning Guys, now i have my rolling Chassis rolling (and it sure looks good with the 16inch rear wheel and XS750 front end!) its time to take on the task of the engine rebuild. I'm looking for basic photos of the very first stages i.e. top crankcase, crank insert, primary and secondary shafts...
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    Another Rotor question

    Guys, following on from my recent Rotor, ignition questions, I have a 1980 bike, pick-ups, Stator and TDI unit and combined Rec/Reg all good. but no TDI Rotor I have 2 options, buy a Rotor from Ricks (comes to quite a bit with Import etc) or fit a magnet as per Gonzo project. My Rotor is...
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    Fitting a Yamaha XS750 Front End

    Hi Guys, I did say I would do a brief write up once i had this sorted and now i finally have. Bit of background as to why i fitted an XS750 front end: My bike is a basket case, I believe intended to be made into yet another Cafe Racer. The front end that came with the bike was a set of R6 USD...
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