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 Post subject: Re: project RETRO
 Post Posted: Thu Mar 08, 2018 9:31 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
as the inlet stubs are too big for the inlet rubbers I have been round to see Taff and discuss the way forward with modifying my new carbs!!

i have removed the inlet stubs from the carbs and they are going to get some turning action to slim down the ends.


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 Post subject: Re: project RETRO
 Post Posted: Sat Mar 10, 2018 8:54 pm 
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Knob Magnet
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just managed to purchase some GSXR1100 (1052cc) cams to go in the bandit head, should help it breath :)

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 Post subject: Re: project RETRO
 Post Posted: Sun Mar 11, 2018 1:28 pm 
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Knob Magnet
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TMR inlet stubs now back from Taff,  shouldn't have a problem with getting the carbs on the rubbers now,  need to get the engine back together so i can do a test fit.


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 Post subject: Re: project RETRO
 Post Posted: Mon Mar 12, 2018 5:16 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
bloody stuck from doing anything, as the piston ring compressors i ordered two weeks ago still aren't here!!

pistons are sitting in there nice little boxes just waiting to be fitted, just have to sit and wait. ​​​​​​​

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 Post subject: Re: project RETRO
 Post Posted: Mon Mar 12, 2018 8:12 pm 
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Hornet Lord

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Location: Coventry/Sometimes Blackburn
http://www.terriblerider.com/new-blog/2 ... ompressors


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 Post subject: Re: project RETRO
 Post Posted: Mon Mar 12, 2018 8:22 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
anz243k wrote:
http://www.terriblerider.com/new-blog/2015/12/9/homemade-piston-ring-compressors


was thinking along them lines :) see what i can come up with tonight

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 Post subject: Re: project RETRO
 Post Posted: Mon Mar 12, 2018 10:15 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
been and fitted base gasket and mounted pistons with rings.

just need the ring compressors   :notme

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 Post subject: Re: project RETRO
 Post Posted: Tue Mar 13, 2018 2:24 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
had a message saying that ring compressors were "out for delivery" so whilst i am waiting i did a test fit of carbs on head.

at first they didnt want to seat, but after a quick inspection i found that a sharp edge on one of the inlets was digging in to the rubber rather

than slipping home, so quick bit of "emery cloth" action and all was good.

tight fit, but not over tight and wont be difficult to mount once head is on engine again


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 Post subject: Re: project RETRO
 Post Posted: Tue Mar 13, 2018 2:47 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
ooooh look what just turned up,  onwards......................................


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 Post subject: Re: project RETRO
 Post Posted: Tue Mar 13, 2018 9:43 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
got the slugs to fit in the holes, but not with the Ring compressors that i had waited so long for, they were just too big and bloody awkward to use, so i ended up with the good old chopped up cider can and zip ties to get the job done.

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then got the head mounted up, and tightened in place, but not torqued down yet, so i could do a carb test fit.

almost perfect, although they are JUST touching the tank on one side, got around 1mm clearance on other side!! wont take a huge amount of work to sort out.


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 Post subject: Re: project RETRO
 Post Posted: Wed Mar 14, 2018 1:57 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
played around with carb fitment a bit more, really not much more i am going to be able to do with moving them!

if i shorten the inlet stubs by more than 7mm then the float bowl bolt will hit the generator mount. so that rules that out.


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but by removing the carb top gaskets, that are quite thick, i can get this sort of tank clearance with the carbs bolted up tight on the inlet rubbers, might just need to fit some anti vibration rubber bungs to the bottom of the tank, to keep them out of contact.


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cam chain tensioner turned up, seems to be very good quality, got oil seals on shaft to stop oil leaks.


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 Post subject: Re: project RETRO
 Post Posted: Wed Mar 14, 2018 2:22 pm 
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True Horneteer
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Location: In The Garage
The engine kitted out with those pistons and carbs looks absolutely mint! :love

Loving the engineering skills on display here :clap


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 Post subject: Re: project RETRO
 Post Posted: Wed Mar 14, 2018 2:40 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
Cheers Hoon :)

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 Post subject: Re: project RETRO
 Post Posted: Thu Mar 15, 2018 11:13 am 
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Knob Magnet
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Location: Catterick, North Yorkshire
will try to get the motor back together today, sorted the last bit of paintwork last night. got the oil return pipes

rubbed down, rust treated and paint done, then left on radiator for the night, they weren't half as bad as most seem to be, so

didnt take a lot of prep.

fitted the bandit cam sprockets to the GSXR1100 cams i got from Clivegto (cheers mate ) I got the vernier gauge on them and as with most engines the exhaust cam

is almost the same lift between the two engines, BUT the GSXR cam has around 1mm more lift and a lot more duration


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 Post subject: Re: project RETRO
 Post Posted: Thu Mar 15, 2018 5:19 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
right, after a bit of research and some more measurements it looks like l am on to a winner.

i did a test fit of the carbs where they will sit with shorter inlet stubbs/rubbers with the tank fitted.

it is a very close fit, throttle cable bracket at top of carbs might need adjustment, and a couple of mm might need removing

from the gen bracket. fuel tap will need to go back to OEM rear position too.


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but it will give me the required tank to carb top clearance that i need, even with the thick gaskets fitted.


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 Post subject: Re: project RETRO
 Post Posted: Sat Mar 17, 2018 3:47 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
bit of a slow day today, so not doing much, did something nice and easy.

took the oil catch tank off and stripped it down, cleaned up the joints of sealant and made some

gaskets out of cork/rubber mat i had laying around.


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 Post subject: Re: project RETRO
 Post Posted: Sun Mar 18, 2018 9:00 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
too bloody cold to spend a lot of time in the shed today, so didnt do much other than re fit the catch tank, battery and sort out some wiring under the seat.
been round to see Taff and arrange for the shortening of the inlet stubs, once the new rubbers turn up, so i can work out how much needs to be taken off.

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 Post subject: Re: project RETRO
 Post Posted: Mon Mar 19, 2018 5:40 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
just a little bit of Christmas today,  nice bigger  & shorter GSXR1100 inlet rubbers :)

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 Post subject: Re: project RETRO
 Post Posted: Tue Mar 20, 2018 11:18 am 
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Knob Magnet
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Location: Catterick, North Yorkshire
have had a play with the new rubbers (oh er misses!!) old ones were 49mm deep, new ones are 36mm so got me a bit of forward movement with them.

inlet stubs that were machined to fit the GSF rubbers are now not a good fit in the new ones, but not a problem as i will now be getting them shortened by around 20mm, so will get the ends machined to match the new rubbers.

i am going to need to match the head inlets to the new inlet rubbers, not massively out with each other but enough to leave a step that will be restrictive if left.

i have been to Taff's and left him to sort them out.

whilst i was playing with the carb fitment I came across a very neat Yoshimura  solution to throttle cable bracket to engine clearance problems.

when i held the carbs up to the rear of the head, the bracket was touching where the cam cover would sit, thought i would have to modify the bracket, but on closer inspection the bracket has an extra mounting hole already incorporated to allow the bracket to swing rearwards and give the required clearance. saved a lot of pissing around

the only two areas of concern now are :-

1) the throttle cam clearance on the rear of the cam chain tunnel where the bolt head from the chain buffer is.

2) bottom of carb No3 clearance on alternator bracket

I think that problem 1 can be sorted with the use of a bolt with a smaller head, problem 2 dont look at all a worry as the carbs seem to sit at a better angle with the new rubbers and there might actually end up being clearance between the two with the carbs bolted up tight.

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 Post subject: Re: project RETRO
 Post Posted: Tue Mar 20, 2018 11:19 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
sat at the computer and changing some of the dull mild steel bolts on the TMR's for nice shiny stainless steel ones.

did the duel stack base bolts and the float bowls, just need to do the carb tops to finish it all off.


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 Post subject: Re: project RETRO
 Post Posted: Wed Mar 21, 2018 1:37 am 
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True Horneteer
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Quote:
whilst i was playing with the carb fitment I came across a very neat Yoshimura solution to throttle cable bracket to engine clearance problems.


Very nice touch by Yoshimura - such a classy set of carbs.


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 Post subject: Re: project RETRO
 Post Posted: Fri Mar 23, 2018 9:10 am 
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Knob Magnet
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Location: Catterick, North Yorkshire
another slow night on the tools, managed to get down the shed for around 10 min's, and only
to swap some stainless steel bolts from the Kehine FCR carbs onto the new TMR's.
they are now fully S/steel (well except for one M5 x "bloody long" bolt that holds the carb bank togethet) sat on my computer desk awaiting word of the inlet stubs 8o

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 Post subject: Re: project RETRO
 Post Posted: Sat Mar 24, 2018 8:46 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
newly modified inlet stubs now back from Taff

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went straight down the shed to do a test fit and check for clearances. just needed to remove around 2mm from the alternator mount for the bottom of the bowl to clear


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rest of them are mm perfect for fit and clearance on rear of engine block/cam chain tunnel.

but best of all there is now loads of carb top to bottom of tank clearance. result  

I used the tank from the 600 for the test as it hasnt got the fuel tap fitted yet.


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 Post subject: Re: project RETRO
 Post Posted: Sun Mar 25, 2018 2:52 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
went to work today on sorting the inlet stubs to inlet rubber alignment, then

got on with the inlet rubber to inlet port alignment.

inlet stub to rubbers at start

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after a bit of work with the dremil

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then onto the head, started off like this.....

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finished off with this


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 Post subject: Re: project RETRO
 Post Posted: Sun Mar 25, 2018 9:51 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
head now back on the bike, torqued down and cams fitted

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 Post subject: Re: project RETRO
 Post Posted: Mon Mar 26, 2018 9:28 pm 
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Knob Magnet
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all torqued up and valve clearances done

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 Post subject: Re: project RETRO
 Post Posted: Tue Mar 27, 2018 9:57 pm 
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Knob Magnet
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continued to put the motor back together, sorted the cam cover and fitted a GSX600F breather box with the rear facing outlet. also re fitted the cam oil lines


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then because the inlet rubbers are larger diameter the oil feed hose to the top left of the engine was too short and was squashing the rubber out of shape, this would have made it

difficult to get the carbs to seat, so i cut some more hose and made a new fitment but slightly longer, fits like it was made for the job


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 Post subject: Re: project RETRO
 Post Posted: Wed Mar 28, 2018 9:51 pm 
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Knob Magnet
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sorted the carb fitment, as the nice new clamps for the inlet rubbers turned up today, pretty tight fit and bit of a pain to tighten, but tighten they do.

got the throttle cables fitted, nice smooth action, should be with all them inner bearings on the slides.
then went to work on the oil catch tank hoses.


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 Post subject: Re: project RETRO
 Post Posted: Fri Mar 30, 2018 9:47 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
getting close to start up time, now got coils, plugs, exhaust and oil filter fitted.

turned her over on the starter till the oil got up to pressure to check for leaks, and as you would expect there is always one!!! at first i thought

it was one of the oil hose connectors on the sump, so i had to remove the exhaust to be able to get to them, checked they were tight and re did the oil pressure, still oil down there!!

turned out to be oil filter seal wasn't good, so off with that and fit new seal, jobs a good un, ended night putting exhaust back on.


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 Post subject: Re: project RETRO
 Post Posted: Sat Mar 31, 2018 3:25 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
https://youtu.be/RewcfrFW1e0

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 Post subject: Re: project RETRO
 Post Posted: Sun Apr 01, 2018 7:38 pm 
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Knob Magnet
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didnt see the sense in going on with the build knowing i had a bad joint in the oil hose, so went to Halfords and got a 

selection of sealing washers to see what would fit the best.


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was well happy with the rubber and metal one (cant remember to proper name for this type of washer!) fitted like a glove.


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now sorted and both hose adaptors done with new sealing washers  gave bike another start up, checked for any leaks, looks to be sorted.

going to get on with doing the tank and moving the fuel tap next.

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 Post subject: Re: project RETRO
 Post Posted: Sun Apr 01, 2018 10:03 pm 
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Knob Magnet
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sorted the tanks on both bikes tonight, swapped over the pingle to the rear and the blanking plate to the middle fitment points.

had to remove the fillet plate to get access to the tank inner, but all good now.

GS production line 

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 Post subject: Re: project RETRO
 Post Posted: Mon Apr 02, 2018 9:16 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
re positioned the fuel tap back to the stock fitment,


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also removed the window from the filler plate and fitted the blanking plate. seriously thinking of getting the fuel filler plate anodised black?( except for the fuel cap)


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 Post subject: Re: project RETRO
 Post Posted: Wed Apr 18, 2018 1:38 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
i have had an idea floating around in my head for a while, think i will look into making it happen sometime soon

going to get the matching rear to go with this front and fit them, i know the front will drop straight on, but the rear might be a little bit

more work, but it is a 6" rim that is the same as i have on at the moment


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 Post subject: Re: project RETRO
 Post Posted: Fri Apr 20, 2018 8:13 am 
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Knob Magnet
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Location: Catterick, North Yorkshire
i have just brought the matching rear :Lick  soon as it gets here i will go to work on making it fit 

i have also made an offer on the matching sprocket carrier and cush rubbers :angel

bonus point is that i have all the Ti sprocket nuts and bolts for this wheel in my box of bits ready to fit :p

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 Post subject: Re: project RETRO
 Post Posted: Fri Apr 20, 2018 8:44 am 
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Knob Magnet
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Location: Catterick, North Yorkshire
if i can get it all to fit and align right then i think it will need one of these bad boys.
as the floating rear disc that is fitted at the moment will have to go on the 600.

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 Post subject: Re: project RETRO
 Post Posted: Fri Apr 20, 2018 6:29 pm 
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Knob Magnet
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well @#%$ me its fun :) just did a quick 50 mile test, throttle response is instant!!! runs smooth and clean, pulls well without hesitation, only slight niggle is its still a bit rich on the pilots, little bit snatchy at low speed in first and second, pilot screws are just under 1 turn out, think i will turn them down to 3/4 out and see how that goes :)

but for a first run it was very pleasing, will keep it under 4k rpm till i have got around 150 to 200 mile clocked up, then up a bit.

ordered one of these to go with the front i already have

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 Post subject: Re: project RETRO
 Post Posted: Sun Apr 22, 2018 6:26 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
took her out for another 60 odd miles after adjusting the pilot screws.

did some adjustments in the shed this morning, turned then down to 3/4 turns out, but that resulted with hanging revs, so that was too lean.

so back off and set them at 3/4 and a bit out. seemed to be ok not holding revs.

but once out on the road seemed to be worse than yesterday for being snatchy at lower revs!! looks like i will need to do a bit more fiddling yet, but motor is sweet

and running well.

whilst i had the carbs off i fitted a remote idle adjuster from the GSX600F carbs that came off the GS 600 build


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 Post subject: Re: project RETRO
 Post Posted: Tue Apr 24, 2018 1:28 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
have now re set the pilot screws to 1 turn out, will see how that goes for next time!

wouldn't be too bad but Mikuni TMR manual is in Japanese FFS and i cant find an English version anywhere on the web

and to make things difficult the PAJ (pilot air jet) don't look anything like the one in the pictures!

I think looking at the illustrations that i have the jetting settings sorted, but as i cant speak Japanese, i am not entirely sure

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 Post subject: Re: project RETRO
 Post Posted: Tue Apr 24, 2018 1:41 pm 
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True Horneteer
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I find observing the trial and error/fine tuning stage of the carburetor installation/modification process fascinating.

As well as skill and knowledge it must also take an enormous amount of patience and perseverance to get everything spot on.


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