Project Katmandu: GS rebuild

[sycomoto]

Loads mate

Always have a stock of odd ones. Push 2or3 down the inlet port and exhaust followed by a soft plastic blanking plug then cover the port with masking tape and then double duct tape. Just remember when undoing it all have the Hoover to hand sucking up all the bits stuck in the folds.

 

[pete.keys]

catching up - may

Been flat out with work and oter stuff over the last few months. I can't believe I haven't posted for three months!!
I'll try and bring the thread up to date with what has been done chronologically

First back in early May Rob Farmer of this took delivery of my gear box, stripped, cleaned and rebuilt it, and has it back to me in around a week.

This was what it started like

Rob spotted a crack where the clutch cable mounts. It looked like it had been like it for some time. To be safe Rob managed to source me a new case

Rob took lots of pictures on the state of the rebuild

Here is it clean

Rob reckoned the internals were in pretty good shape and the box it self was probably rebuilt not that long ago.

And here's it is all up and complete

 

[pete.keys]

may - aquired this and wonder if it could be used?

maybe for the next project ...

 

[pete.keys]

May - June Frame Work

Frame back from shot blasting

John Dogbytes did his stuff to the frame using the metal that had been laser put from his patterns

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[pete.keys]

May-June

Thinking about tank painting options / decals

Not very inspiring ... any suggestions ???

 

[pete.keys]

June - final prep before powder coating

removing bearings from the monolever

Drilling out the key lock as I lost the key :-(

Of course I removed the headstock bearings using a dremel to cut through the race that is in the headstock. Really difficult to do without "nipping" the headstock metal - which I did :-(. I'm sure I took photos of this but I can't find them

 

[pete.keys]

June /July

Still wondering about how to mount the instruments.

I wan't to keep the g/s screen, but I think the binnacle will have to go.

Found a larger head light.

Thinking about the screen and headlight static, and the instruments mounted on the top yolk somehow.

Aquired a fairing spider - can I remodel it to support the binacle and headlight?.

Will these two screws alone mange to hold the weight? the spider is surprisingly heavy?

Anyone know what the thread on these captive threads are?

 

[pete.keys]

July: frame back from powder coating

This is what Ral5010 looks like

All this done for £100!! A real bargain.

 

[pete.keys]

July - bringing progress up to date - frame rebuild

So just bringing progress up to date.

Replaced front wheel bearings

Replaced headstock bearrings (from DRZ400)

All new swinging arm pivots/bolts/springs

The powder coating company masked off the end of the swinging arm

So painted the bare metal

and replaced bearings

Tripple clamps in place

And add a few more bits .. and voila ...

 

[pete.keys]

Engine rebuilt by Richie Moore

And today a big jump forwards.... collected my engine from Richie Moore

 

[igormortis]

Nice progress!

But... did you leave the lower tank brackets on the frame when you powdercoated?

 

[Box’a’bits]

Did you leave the lower tank brackets on the frame when you powdercoated?

Post 344. They were brazed on.

 

[pete.keys]

Post 344. They were brazed on.

Yes they were brazed on. I was going to cut off the superfluous brackets to clean up the look up but Dogbytes asked me to ratain them as he was nervous about all the weight in the 43L tank

 

[pete.keys]

And today a big jump forwards.... collected my engine from Richie Moore

I should have added the important bits

• Omega long skirt pistons
• Lightened and balanced crank
• Balanced rods, pistons and flywheel
• Modded cyclender head with 44mm in and 38mm single piece valves
• New mains and big ends
• New oil pressure pump
• New timing chain assembly
• Sachs racing clutch
• New rocker bearings & plastic spacers
• New valve springs
• All parts vapour blasted and ultrasonically cleaned

 

[Benjamin M]

So are you keeping the dodgy looking swinging arm then, having clearly invested so much in the engine?

 

[pete.keys]

So are you keeping the dodgy looking swinging arm then, having clearly invested so much in the engine?

what my perfectly engineered work of art

I have given Richie Moore a new one to do for me .. but you know Richie ... perfection takes time .... .....so I'm using this one for now.

 

[Shurv]

Lucky sod, I've been waiting fast approaching a year fior Richie to get my bike in for the finishing touches.Perhaps now he's finished your engine, he may have time for me............

 

[pete.keys]

Lucky sod, I've been waiting fast approaching a year fior Richie to get my bike in for the finishing touches.Perhaps now he's finished your engine, he may have time for me............

hopefully he'll finish my carbs first ... then he's all your

 

[pete.keys]

Engine shots

Thought I'd post up some more pictures of my lovely new engine ...

With Silent Hecktik alternator and ignition pickup:

Nipon denson starter

 

[pete.keys]

Now how to mount the front screen

Started with a fairing spyder I acquired off fleabay

Cut off the bits I don't need

And made a fancy cardboard headlight and screen holder

Do you think it'll hold?