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Post by dusty350 on Jan 2, 2020 8:25:36 GMT 1
Hi Chris I removed just the larger one in each carb. There is a very small drilling/jet behind it that can get blocked. It's a 4.5 mm brass ball, I got a pack of 10 off ebay ages ago. If you struggle I have a couple spare I could send you. I tend to do all my carbs now, and the balls need to be removed to clean them properly. Dusty
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Post by sidney81 on Jan 2, 2020 11:19:11 GMT 1
Hi Chris I removed just the larger one in each carb. There is a very small drilling/jet behind it that can get blocked. It's a 4.5 mm brass ball, I got a pack of 10 off ebay ages ago. If you struggle I have a couple spare I could send you. I tend to do all my carbs now, and the balls need to be removed to clean them properly. Dusty Thanks dusty sounds like it's worth doing then ,that's good of you thanks looks like careful drilling !!!
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Post by dusty350 on Jan 2, 2020 20:38:10 GMT 1
Popped into the engineering place this morning. Glen,the welder, is there on his own, making dinosaur cages for "Jurassic World", so he was pleased to have a distraction for an hour !! The tube needed for adding to the Allspeed downtubes was an odd size, so we found some with a 1mm bigger outer diameter, and then Glen turned them down on the lathe, cleaned up the downpipes where I cut them all those years ago, and welded the new extensions on. I didn't go for anything fancy in the end, for 1 main reason. I was messing about with the pipes last night, working out exactly how much tube needed adding, and the memory bank coughed up a memory from the 1980s ! I cut the exhaust downpipes after I had the 430 conversion done by Stan. The cylinders get approx. 7mm milled off the bottom, which means the exhaust port sits lower than standard. This in turn throws out the angle the pipes sit at, and I cut the pipes thinking it would restore the rear mount alignment, which of course it didn't ! So I've now altered the rear mounting hole on the pipes and it all lines up. Nice to have the downpipes the correct length again; 20200102_184525 by dusty miller, on Flickr Whilst the pipes are off, I thought I would whip out the wheels for a good clean - they are filthy from standing for so long. I will also have the forks out to polish out some minor blemishes too, that's tomorrows job. I spent a bit of time making up a new bike stand from 1 eight foot length of cls - cost me £3.00; 20200102_183923 by dusty miller, on Flickr I can have both wheels out safely with the bike perched on that. When the rear wheel comes out I will lengthen the Hagon shock a bit to get the back end up a bit - it sits a tad too low at the mo. Dusty
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Post by donkeychomp on Jan 3, 2020 0:00:13 GMT 1
Is the Hagon shock adjustable like that? And YPVS forks (slaps head) I forgot the bike had those. I do like that mod, they just bolt straight on. I drove passed the engineers place today, was surprised it was open. Didn't see the Tesla so I assumed it had broken down yet again Alex
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Post by dusty350 on Jan 3, 2020 8:24:07 GMT 1
Hi Alex The Hagon is a length adjustable one. Seems to be one of the newer types that look better made and better finished than the originals. Ian bought new stanchions for the forks, but they are not "waisted" at the top like the originals I had fitted (Triggers broom again !!) There are a couple of minor blemishes on them so I thought I would polish them out before fitting it all back together. Glen is at BWB on his own this week - Clive and Barry start back on Monday. He has 7 of these cages to make so wanted to get ahead. It's so nice having all the tools and knowhow to do jobs like the Allspeeds. It took an hour, and we spent half of that gassing and searching for the correct tube. It did make me realise that I must get my own lathe !! Dusty
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Post by veg on Jan 3, 2020 8:42:13 GMT 1
Don’t forget the baja foam grips 👍
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Post by dusty350 on Jan 3, 2020 9:06:48 GMT 1
It's worn Baja grips in the past Veg. Once you fit foam Baja's, you gain a cruise control facility, due to the grips not allowing the throttle tube to return to it's stop ! Particularly useful on the motorway ! (until the engine blows up !!) Dusty
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Post by cbm on Jan 3, 2020 9:14:35 GMT 1
Loving the thread Dusty, as much as I enjoyed owing/riding the LC2 I had until a year ago (it also went back to the the Guy who'd rebuilt it) the Air Cooled bikes are my era. As for owing a lathe you'll end up like Yamark making things just because you can, have to admit I was the benefactor of one his "tests"
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Post by dusty350 on Jan 4, 2020 21:02:15 GMT 1
Yea, Mark has knocked a couple of bits up for me too He's pretty handy with his lathe So I've had both fork legs out for polishing, mainly to clean them up a bit and to remove some minor marks in the alloy. You can see a difference between the left and right; 20200103_150530 by dusty miller, on Flickr Another issue I discovered were the lock stops on the bottom yoke. When I first got the bike the stops had been drilled through to allow a small bolt to pass through and make the stops "adjustable". I think this weakened them, and a few tank slappers and crashes when it was a Brands race school bike didn't help the stops maintain their effectiveness. Ian did get the bike down to Maidstone and got it on a motoliner which showed it was 2.5 mm out, so he had that corrected, but the lock stops looked decidedly worst for wear when I took a look; 20200104_095517 by dusty miller, on Flickr The one on the left has had, what I guess, is liquid metal added to it to give it some shape, but it's not going to be something ideal for repairing a lock stop ! Bottom yokes are silly money on ebay, plus it's an original part of the bike from when I first had it, so I decided to cut the ropey stops off with my Dremel. I then centre punched and drilled a pilot hole through, then gradually bigger holes until I could fit an M8 bolt either side to act as new stops; 20200104_120403 by dusty miller, on Flickr Turned out well. The powdercoating is looking tired in places, and I'm resisting the urge to strip the whole bike down to get it redone at the moment. It will happen, but not until I have reworked a few other areas on the bike. I want to change the headlight, and fit it slightly lower, which will enable me to mount the Koso lower down. I will make a bracket that mounts under the top yoke to enable me to do that. I'm also changing the headlight brackets, as the billet items that are fitted are very chunky. I've got some cheap chrome items that I will fit for the time being. I originally fitted the ignition barrel in a pattern Lc headlight bowl, and Ian did the same with this new headlight, but I may try and find a different location for the barrel. There are lots of little jobs I can do to tidy it up Dusty
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Post by dusty350 on Jan 9, 2020 21:06:55 GMT 1
I've been doing lots of little "detailing" jobs this last few days. Gave the wheel a really good clean and polish, and fitted new discs and disc bolts,and some rim decals; 20200109_192744 by dusty miller, on Flickr The magnets for the speedo pick up had been glued into the button head bolt. This meant you had to prise them out to undo the bolt to get the disc off, so I bought 2 M8 magnetic headed bolts for a proper solution; 20200109_160147 by dusty miller, on Flickr I've changed a lot of bolts on the bike too. Originally there were a lot of acorn nuts fitted, but I've been removing them and replacing with stainless bolts and nylocs - minor jobs that make a big difference overall. I made a bracket for the Koso instrument - it was mounted to the handlebars before and sat very high, but the bracket bolts under the top yoke and the Koso now tucks in quite nicely; 20200109_192726 by dusty miller, on Flickr I'm also experimenting with different bars. I've just fitted some Renthal straights but they are not ideal - clutch cable and brake line don't like the new position, so the ultra lows might go back on. Definitely want to change the headlight and brackets - probably a pattern Lc headlight - that's what I had before. I will keep the ignition barrel in the headlight shell - it's actually the best place for it. Next job will be back wheel out for a clean and polish, new disc and decals, adjust the shock length and polish the torque arm and caliper carrier. I have found some standard, silver chain adjusters so will fit those and lose the nasty red adjusters I fitted years ago !! Dusty
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Post by andy748 on Jan 9, 2020 21:39:53 GMT 1
Looking mighty fine Dusty, quality workmanship, i am liking air cooled Rds more and more as i get older! Andy.
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Post by dusty350 on Jan 9, 2020 21:57:49 GMT 1
They are great bikes. A bit heavy and dated when compared to an Lc !! I checked the dry weight of a standard Rd 400 against a standard Lc - the Lc came out approx. 22kg's lighter !! And you can notice it when moving the 400 around ! But I love them anyway. I'm not planning on changing this hugely - the biggest change may be a Metmachex swingarm, but apart from that, it will basically stay the same. I managed to get a Nova on the German frame I have, so that will be another project bike. The 400E engine I picked up will get a full rebuild with some trick bits, and will go in that frame eventually, meaning this 400 will stay more or less the same. Dusty
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Post by donkeychomp on Jan 9, 2020 23:38:27 GMT 1
Love the key in the headlight idea. Very old world if you know what I mean but really suits the cafe racerness of the whole bike. And I'm as chuffed as you must be for getting a nova for that German frame. Happy days!
Alex
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Post by veg on Jan 10, 2020 8:03:02 GMT 1
Looking really good dusty, like the magnetic bolt as I am using a glued magnet for my koso is it just a straight eBay search? Won’t be long before it’s stripped.
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Post by dusty350 on Jan 10, 2020 8:20:31 GMT 1
Cheers Alex I didn't hold out a lot of hope for a Nova, but was pleased when I got it Veg, I went on ebay and typed in M8 magnetic speedo bolt/Trailtech/Vector/magnetic pick up, and they popped straight up. £7.95 each. They do other types too. This type of bolt works well on a Ypvs disc, but I cant use them on my Rgv front end as they would hit the caliper due to the bolt positioning. I have small stick on magnets for that bike. Dusty
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Post by dusty350 on Jan 10, 2020 21:23:23 GMT 1
Went through some old bike pic albums today, and found a blurry picture that I took the day after the Armageddon on the M25 ! I said early on in this thread that when I removed the right side downpipe, a lot of debris fell out. You can imagine how I felt when I saw this; 20200110_193428 by dusty miller, on Flickr That pic reminded me that I had kept the broken parts as a memento of my near miss. Nearly 34 years later, I still wonder how we got away with it !! 20200110_193159 by dusty miller, on Flickr If you look at the piston you can see a circular mark just above the hole in the crown - that was the gudgeon pin that did that ! One thing that I am aware of now, but not back then, is that the pistons that were fitted were 4l0 items and not original aircooled ones. Whether that had anything to do with the seizure, who knows ? I always thought the circlips had been reused by the shop that did the work a few days prior to the seizure - they never billed me for new ones and were sheepish when questioned after the event. Doesn't matter now of course but serves as a reminder to make sure any work done, is done right !! Dusty
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Post by veg on Jan 10, 2020 22:52:53 GMT 1
Omg not sure what is worse the damage or the paisley rug. Cheers dusty will do a search.
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Post by donkeychomp on Jan 11, 2020 0:21:33 GMT 1
Yikes! I've had a few engines let go but nothing like that! Alex ps thankfully the rug will be long gone...
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Post by dusty350 on Jan 11, 2020 9:42:47 GMT 1
Haha, the rug was in the garage at Mum and Dad's house back in the 80's. Spent many cold nights knelt on that, trying to repair and modify old 2 strokes !! My Dad was an aircraft engineer for BA, and had a comprehensive collection of quality tools that he would freely allow me to use. Owning a stroker in your teens back in the 80's was a steep learning curve, but I only ever called on his help when it came to electrickery as that was his speciality. An Rd400 couldn't faze him when his bread and butter was a 747's c**kpit avionics, and the wiring on a Rolls Royce Rb211 Turbofan !! Unfortunately, I didn't inherit his ability with wiring !! Dusty
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Post by earthman on Jan 11, 2020 10:59:53 GMT 1
Haha, the rug was in the garage at Mum and Dad's house back in the 80's. Spent many cold nights knelt on that, trying to repair and modify old 2 strokes !! My Dad was an aircraft engineer for BA, and had a comprehensive collection of quality tools that he would freely allow me to use. Owning a stroker in your teens back in the 80's was a steep learning curve, but I only ever called on his help when it came to electrickery as that was his speciality. An Rd400 couldn't faze him when his bread and butter was a 747's c**kpit avionics, and the wiring on a Rolls Royce Rb211 Turbofan !! Unfortunately, I didn't inherit his ability with wiring !! Dusty Sounds like a great dad, did he try and steer you into the aircraft industry at all? You became a firefighter right? Were that something you knew that you wanted to do from an early age??
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Post by dusty350 on Jan 11, 2020 22:24:21 GMT 1
Always wanted to be a Fireman, although I did have an entry test for BAE at Farnborough after leaving college. One of the things we had to do was make a straight piece of wire into a intricate shape that they showed us before hand, with 2 pairs of pliers, and you had a couple of minutes to do it. Mine went well until I thought I would just tweak it a little, and promptly snapped it in half !! The Fire Service was more suitable for me as I got to break lots of things on purpose !! So the little jobs on the 400 continue. With the back wheel out, I was able to polish the wheel and apply the rim decals; 20200111_101357 by dusty miller, on Flickr When I first owned this bike, the rear wheel spindle was always too long - I think they differed between models - and I had an odd spacer fitted that allowed the nut to work properly; 20200109_212832 by dusty miller, on Flickr I don't know how, but a box of spares I've had forever turned up a correct spindle - probably an Lc item; 20200109_214649 by dusty miller, on Flickr So I can now lose the spacer. The red chain adjusters have gone too; 20200111_150056 by dusty miller, on Flickr Whilst the wheel was out I adjusted the shock so it sits the swingarm 1.5cm lower at the back. This is allied to a modded Lc arm - I had a longer bracket welded on years ago to help with a saggy rear end ! 20200111_150131 by dusty miller, on Flickr I polished the caliper carrier and torque arm too; 20200111_145909 by dusty miller, on Flickr And fitted a new disc to match the fronts. The other job was the bars. The straights just didn't allow the brake lines and clutch cable the routing they need, so I modded the Renthal low rise bars that had been fitted. They were anodised in gunmetal originally, so I got that finish off with a brillo style pad in my angle grinder, and then polished the bars. As standard they looked too wide, so I cut an inch and a half off each end too. They look a bit more like Lc bars now, and better suited to the bike I think; 20200110_212331 by dusty miller, on Flickr That pic makes them look wider than they are - I'm pleased with them now. Dusty
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Post by donkeychomp on Jan 12, 2020 0:14:33 GMT 1
Never noticed the breather pipe before, a nice touch and looks good. I have, however, noticed the brake and clutch levers and reservoir. Exactly the same as the ones you gave me ages ago that are now on the Popsicle!
Alex
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Post by dusty350 on Jan 12, 2020 10:08:56 GMT 1
I fitted that breather to the original tank on the bike, and Ian transferred it over when he bought the new tank. Doesn't really need it but I thought it looked trick then, and still do now ! Dusty
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Post by sidney81 on Jan 12, 2020 17:59:13 GMT 1
Looking brilliant dusty ,hope mine will turn out even a little like yours I would be happy ha ha ,will you ride it over the summer? I hope you do 🙂
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Post by dusty350 on Jan 12, 2020 21:52:45 GMT 1
Hi Chris I would love too, just depends on my back, plus my knee is now playing up again as I've started running again The riding position would suit a Gymnast !!) Put the carbs back on today, and fitted the polished boost bottle and fitted the Yamaha clips; 20200112_175117 by dusty miller, on Flickr Allspeeds are going back on, with new exhaust gaskets and repainted manifolds, plus I bought some Allspeed decals; 20200112_175200 by dusty miller, on Flickr And you can see the pipes now line up properly with the frame mounting point. Years ago I made an ally bracket so I could mount twin horns under the headlight, like an Lc. I've looked at them again and feel they don't suit the bike now, so I'm reverting to a single horn that will mount in the standard way behind the yokes on the frame down tube. I cut down the bracket and left it fitted under the headlight to shroud the bottom yoke; 20200112_175455 by dusty miller, on Flickr I've ordered some proper brake line guids for the front muddie, so once they turn up I will fit the braided lines and bleed the blue spots. Dusty
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Post by veg on Jan 13, 2020 7:46:12 GMT 1
You’re relentless, matts mantle for fast building is going to pass to you. This is far more like a rebuild than a freshen up. It really is looking lovely.
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Post by dusty350 on Jan 13, 2020 8:09:22 GMT 1
Cheers Veg, but it is more a freshen up. There are some things to change that are more involved but I don't want to get caught up in this before I finish the Café Racer build, which is my priority. Plus there is the other 400 engine on the bench that I want to do a comprehensive rebuild on - a small project in it's own right, but I have resisted the urge to strip that down at the moment ! I did buy a nice Rd tank off ebay on Saturday that will go with the spare frame, so I have started parts collecting for that project - already got the front end and a rear wheel for that one. The next thing on this bike will be to tidy up the wiring and the battery box set up. I need to be able to get the number plate at a better angle as it sits right on top of the rear wheel at the mo, which means totally redesigning the back end and relocating some components. Hopefully not as involved as it sounds ! Dusty
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Post by dusty350 on Jan 17, 2020 20:50:06 GMT 1
Been "tweaking" a few areas of the bike this week - small jobs really but they all add up ! The new horn and bracket arrived so bolted that on; 20200117_170335 by dusty miller, on Flickr And I fitted 2 proper brake line guides, fitted the brake lines with new copper washers and tidied up the speedo pick up wire; 20200117_170329 by dusty miller, on Flickr Binned the mudflap from the front mudguard too Another thing I would like to modify is the rear brake master cylinder. It's non standard so wont bolt to the bracket on the frame, and there is a chunky bracket fitted that allows it to fit; 20200117_145958 by dusty miller, on Flickr It looks "complicated", especially when you take into account the lever system that goes through the frame; 20200117_150002 by dusty miller, on Flickr It makes you realise how much things have moved on, even for the Lc's and Pv's. And worst of all, the back brake doesn't even work ! I think the levers and the set up just isn't good enough, so it's got to change. The rear master looks new, or certainly in very good nic, so I plan on making a bracket that will mount to the 2 redundant holes in the rearset back plate, allowing the master cylinder to mount directly above the brake lever, thus doing away with the heavy and ineffective system that is there currently; 20200117_170656 by dusty miller, on Flickr A bit of steel plate should be strong enough, so once I have dismantled the rear brake system, I will offer up the master cylinder, finalise my CAD design, and get it cut. Eventually, when the frame is ready for another powdercoat, I will cut off the original master cylinder mount from the frame to tidy it up. Mouse popped over this morning to have a look, so we pushed her outside to run her up, and I grabbed a pic whilst I was at it; 20200117_092928 by dusty miller, on Flickr I also managed to win a lovely tank on ebay that is mint inside and out; 20200115_105154 by dusty miller, on Flickr 20200115_105139 by dusty miller, on Flickr This is destined for the other 400 that I will be building. The engine for that will be a separate build thread I hope to start soon Dusty
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Post by midlifecrisisrd on Jan 17, 2020 21:07:04 GMT 1
Nice find is that tank 😉
Steve
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Post by dusty350 on Jan 17, 2020 21:21:59 GMT 1
I wasn't really looking to buy a tank yet, but a decent aircooled tank is becoming a bit of a rarity - most are at least 40 years old now. I did approach Tabclassics in Wales about making another alloy race tank like I have on the Café build, but that would have been around the £700 mark, plus they needed the frame taking to them. As lovely as it would be, this tank, supposedly dry stored since 1980, made more sense economically.
Dusty
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