Build Diary
October 2008


Up-to-date again

Whilst messing around with the modified clutch master cylinder (see earlier), I broke the water pump impeller.  Only one flap, but I had to repair that.  This required disassembly and reassembly of all that.  That included taking the clutch cylinder apart, remounting the brackets and such (with threadlock this time).  Also I bolted up the prop-adapter properly (as in damned tight) with a new nut, and put the central retaining bolt and washer in the centre (a bit more belt and braces than necessary, but you can't be too careful with this stuff).

Finally engine in (hopefully for the last time), thanks to my brother Tom for his help

Good news:
1) it fits in and still bolts up
2) we didn't chip the paint
 Bad news:
1) this was the first time that the bonnet was installed and IT DOESN'T CLOSE by maybe 1inch

So I have got a clash between the breather of the cylinderhead cover and the underside of the bonnet.

Lots of head scratching, but the options were:
1) lower engine.  Non-starter as it is already low in the chassis (problems with sump on road, and problems with top rail and exhaust pipe)
2) hole in bonnet. Not appealing.  I have already messed with the bonnet, and it looks niece.  Also there are no other clashes so it almost fits.
3) steal a bit of space in a 3 pronged attack.  Thin the bonnet (managed to get 6mm out of it), slightly raise bonnet (managed to get 5mm), magic with the breather.

Magic with the breather meant do something to get rid of the ugly 1inch box on top of the head.  One option was to blank this off and use a crankcase breather instead, but when I put this to the oldschool suzuki forum the view was that oil might hang in the head which can cause engine failure.  I don't think there is good knowledge on that, but if there is an engine blowing chance it would be best avoided!  Another option was to find a thinner breather, it turns out that gsx600 breather from a Katana is thinner (and after getting one from the USA via e-bay for £2.50 + £5.50 postage it turns out that it fits).  This buys me another 12mm or so.  Hopefully that is enough to get it all nice.  I do need to fit this together tomorrow night.



Wiring wiring and more wiring

Loads of diaries talk of how time disappears when you are wiring.  It is all true.  Anyway it is going quite well.






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