We have been very busy in the workshop, the bike is finished for now and we leave for the South Island next Wednesday.
The clutch is now very much modified, it was a lot of work it now sports 8 FZR 600 plates, a new custom pressure plate, RGV250 springs, custom spring holders and a larger bore master cylinder.
The cases (early type) needed to be modified to take a flange that reduces thrust on the bearing the bearing fitted to later type cases.
We couldn’t do this in house as the welded cases were too tall to fit in the mill, this and the water jet cutting are the two jobs that we couldn’t do between us.
The rear and side brake master cylinder was not releasing properly and was faulty from new. Next time we will be using used OEM rear master cylinders. We have had a lot of problems with the hydraulics but they are all sorted now but it took a lot of time.
The front brakes have been re bled.
A new fuel manifold has been made; the old one had too many pinholes in the Lumiweld to repair.
The new one has a larger more direct overflow pipe to the fuel tank in an effort to stop the carbs being pressurised.
The carbs have been stripped and cleaned and the floats levels checked, the fuel system has been flushed to remove any water and debris left over from making and pressure testing the manifold.
The tank breather in line restrictor has been enlarged.
A gearbox breather has been fitted and piped into the carbs catch bottle.
A clear cover has been fitted to the ignition and a pointer made so that TDC and timing can be checked quickly.
An extra grab handle has been made, aluminium finishing strip around the side wheel guard made and fitted. The platform has been upholstered.
Broken exhaust thermocouple housings have been re soldered, larger grub screws fitted to the drive and coupling sprockets.
The Frame and plastics have been painted. The frame has a gold metallic flake in it the black looks normal in the shed but really pops in the sun. Black is not the ideal frame colour so far as crack checking goes but hopefully with an engine that’s not trying to jump out of the frame cracks may not be such an issue.
The body work was finished tonight so took a few photos.
Pretty pleased with how it turned out, hope we can get it to perform to expectations.
Future plans are a fairing and more porting/tuning hope to get it on a dyno some time after Boxing day.
Number 250 is on the table now for new tyres and a once over before the trip south.