Official Kit build thread. (Picture heavy)

Ok update for today,
Got the entire ductail together over the weekend and the swing arm on.

I went a bit silly and painted the exhaust mount red too.

Same with side stand.

I rounded the screws that were in the switches. So after some dremill work with a round engraving end they came out. I then replaced them with stainless steel Allen key bolts. Meaning tighter fit and better grip on the bolt.

Bolted the tank down to see how firm my work was. The tail is stronger and better bolted down will all new Stainless Allen head bolts and spring washers.

Found out why my front breaks didn't work. I think the picture speaks for it self.

Lucky enough they had brand new pads in them. So no need to get new ones.

 

Also fitted the stainless braided lines off the track bike. 2 lines to the master cylinder instead of all the joins throughout the lines.



Cleaned up the caliper and painted.

Painted the rear brake mount red to add some colour to the black swinga.

Swapped the old throttle for a wire locked tube. And am gravity bleeding the front brakes over night.

 

Yeah mate. But unlike chris I seem to hit roadblocks and pot holes at every turn. I organised to pick up the bike and bam buyer inspection. Then Saturday morning walk into my garage open the door and 2 people standing at my drive was saying they are calling the realestate and organising a inspection. A hour later phone call. So after all that inspection Monday lunch. Just can't wait to be out of this house.

 

Yeah mate. It was the single line into a chamber? Bloky-thingy? That's bolted to the bottom of the triple clamp. Like much prefer the 2 lines from the master cylinder.

 

So I managed to sleep in and missed work today... And decided to work on the bike as well as do this house inspection... I wanted to get more done.. And am goin back out there to get more done soon...

I managed to get the holy headers off the bike and put a more complete and less rust on...I also got the DIC exhaust on as well, But I fear it has some internal issues which will be explained later..

So now i had all the handle bars and switch blokes and throttle on, I decided to crank her over and give kit her official start and run/rev up.... And of course its exactly what she did... BUT still had the No.2 cylinder is still not firing.. So off came the carbis... Thats when i noticed the vacuum line was not on properly and the No.2 carbi boot clip was a little warped out of shape... So I took the boot clip off the parts bike and firmly attached the vacuum line... She fired and idled but still was running rough so I did the pull through technique to all of the carbis and the bikes revs climbed dramatically... So they all have spark and all are getting some amount of fuel from the carbs.. So now Im thinking carbs off with a clean and perhaps re-jetting...

Also having issues with the front breaks not working... the brake fluid is there.. But the pistons are not moving.. It looks like i will be rebuild the calipers after all... Plans for tonight is to get the nose fairing, H frame and clean the rust out of the new tank.. Which i mean slosh some fuel around in the tank to pull the rust of and dump the nasty fuel onto some weeds in the back yard...

 

Oh and I forgot to add, When I was reving the bike the exhaust was making rattling sound.. BUT the exhaust note from this can is well worth the small rattle when you come off the throttle... I do on the other had have the exhaust system off the track bike but it will need some tlc to get it looking decent..

The exhaust tip is probably the worst part.. But I do have to the tools at work to get it a nice weld bead instead of a sanded out corner...

 

Ok so today I thought "stuff it get a different colour brake fluid and bleed it until only the new fluid is in the system." So thats exactly what I did... The previous ways I tried were a zip tie around the lever and throttle.. and a quick pump up the pressure and bleed the line. Both of which didnt build any pressure in the line. Well this time i did it properly... And this is the contraption I used..

So this time I wouldn't have to worry how much I would be putting out of the bleed nipple... And about 5 mins in with a lot of air bubbles then the lever got a firmness about it... Then I changed to the other caliper and bam bother calipers had pressure and grabbed the disc... Made me a happy man as I don't have to do a caliper rebuild.... lol

 

So i went a little over board when i was getting kit back together today... She still needs tank painted but that can wait till after roady... Also there is a very good reason the back wheel is not on the bike before anyone says it..lol

yep even the side vents are red now...

 

hahahaha Well I could put a wheel on it...But it would tempt me riding it up the street and if its running lean.. i really dont want do bad things to the engine..

 

thats been flogged..hahahaha

 

Oh that was on the cards already lol... it was more i wanted the jets done first is all lol

 

OK... So I don't have any pics of what occurred last Saturday.. Was way to excited about the bike actually being complete... I wouldn't say the day was a complete success nor would I say it was a complete failure... So Tyson came over and showed me how to clean carbs.. And I say that man knows his way around a set of carbs... It turns out the reason for number 2 cylinder not firing was a dirty jet which he sorted... So we reset the carbs back to factory and bam she idles and revs with all 4 header pipes with plenty of heat.. No knocks, No cam chain slap and no ticks this made me very happy... So I swapped the stock pipe for the DIC after market one and man the note is that came from it was the heavenly sound only an angels(If you believe in them.. I don't) trumpet could make... So i got stuck into getting the minor details of the bike ready for tank fitment even 2 go pros mounted on the windscreen...

That is when things when bad... Turns out when I was cleaning the tank I cleaned it to well.. Tank was fitted then we added the fuel, well we soon found out there was a hole in the tank just near the tap.. it was leaking every where.. golden 95 premium fuel all over the frame and engine.... So we quickly removed the tank then I thought "crap the paint is only pressure pack" which basically means the fuel has eaten through the paint on the frame and engine... The other problem is I'm missing the trumpet rubbers.. The ones in between the carbs and the trumpets..

But on a plus side Tyson showed me a site where I revs checked the bike and the spare frame and both a clear title!!.. Now after licking my wounds I and devising a plan to sort my tanks out and get kit on the road..

 

So today Tyson helped me out lending me his tank until i sort out my green one.... Annnnnnnnnndddd......
I thought the black was over done but it turned out really good i think... And of course i took it for a ride.. and the clutch was slipping like.... umm well something slippery?? i used the lever adjustments and it got a little better but not much... So when I stopped took a peek at the adjuster near the case and say this...

Honestly I'm surprised it went into gear.. It does explain why it was slipping...
Apart from that it had a lot of flat spots but I'm thinking that is because of the lack of seals for the carbs and the airbox not on tight... Which will be fixed when my litetek kit arrives during the week.... The only other thing is the oil needs topping up. When I changed the oil i didnt account for the filter change too so it just needs topping up, its sitting just above the low line and the tapets where making some noise.... Cheers again to Tyson for the lend of the tank so I can trouble shoot the bike while i fix the tank..
there is the other pics I but are sideways for some reason??

On the last pic i really like the stainless allen head bolts on the black...

 

also attached is the picture of the tank liner I was going to use... Anyone had any dealings with it??