Power valves 2ma

[yanw]

Can I ask what grade of ally-alloy you used please?

[oldiggy]

Hi it's 6082 T6 H30 medium strength ally I got it from Alum-droitwich eBay hope this helps.

[oldiggy]

I bought a length of 12 mm stainless bar from the same place for £7 I might have a go at making a shift rod if  I can figure out cutting the splines.

[oldiggy]

I had a go at making a shift rod. I turned the lathe tool on its side and slowly removed metal to form the spline backwards and forwards. I turned off the old knackered bar from the shifter and mig welded it onto new shaft, polished up the area where the seal runs. Any thoughts on those mitaka pistons ? The previous ones I bought +0.75 and didn't use have 1KYP stamped inside and PTK 120 on the box.

[m in sc]

you single point broached a shift shaft? thats impressive. Im going to have to try that at some point, never crossed my mind.   ive tig welded an end on before, but thats just downright clever.   

[oldiggy]

Thanks, I think you can run a Knurl onto a bar but I couldn't grasp which  pitch of Knurl wheel to buy plus it might not dig in to stainless steel. The small diamond shape bit appeared to be the same angle so I used that. I answered my own question about those pistons I was looking for some other parts and saw they are TDR250 pistons I'm not sure why the skirt would be longer  than tzr 1kt. Renewing clutch basket for mitaka today and ordered new inlet rubbers £200 ouch !

[oldiggy]

  The plastic sprocket cover shift shaft hole is 14mm I'm not sure if this is standard or worn so I took another 2mm out and fitted a needle bearing, might give a bit more support to shaft. I ordered a clutch set about 9 yrs ago there was some delay and they said they had to get it from the US ?? More delay it finally turned up and no metal plates,more delay ok got it all but by that time I couldn't be bothered with the clutch it was only a bit grabby on pull away. Fast forward 9 yrs went to fit into my nice new basket metal plates are incorrect and two of the friction linings are of a different material🙄 my original plates are good so went back in. Spent a couple of days cleaning the green death out of the carbs for the hundredth time I think it's time I purchased an ultrasonic cleaner. Having a problem with my hand pump to check engine is holding pressure but should be ok as everything new.

[oldiggy]

Metal plates x6   1.5mm thick 30 teeth 123.5 width the only check on eBay lists Suzuki .

[oldiggy]

If anyone makes their own exhaust manifolds they can be done cheap, if you go to a BMW car dealership these gearbox clutch thrust bearing sleeves are always in the scrap metal bin they are hard material with some sort of coating and don't rust they fit nice into 2ma barrels when cut.

[oldiggy]

I've realised I'm not twenty anymore as I lifted that engine back in on my own, after huffing and puffing bugger I forgot the rubber engine mount washers so struggled again. After repairing stator loom after various wires rubbed through and damaged I didn't use loom tape but got some wiring spiral to stop any more damage. Power valves working and in sync. Went to check spark kickstart not engaging I had put a new spring on the back gear I had visions of taking apart but after a few jolts with the lever it started engaging and works every time maybe just where parts have been cleaned and dry. No spark WTF ! Check fuses rechecked wiring and connectors voltage testing going through wiring diagram 😅 guess who didn't turn run button on 🙄 sparks fine so I would just like to offer myself as moron of the week.

[biggz]

No spark WTF ! Check fuses rechecked wiring and connectors voltage testing going through wiring diagram 😅 guess who didn't turn run button on 🙄 sparks fine so I would just like to offer myself as moron of the week.

If only I'd known there was an award... I'd need a bigger mantlepiece.

Laurie

PS Please keep a really close eye on those clear oil distribution pipes.

[oldiggy]

Wow how did those pipes melt? I've always used them in the past until they go hard. Oh I nearly forgot can I have moron of the week for next week as well, the neutral light hasn't worked for years, while eng apart I renewed switch and blue wire and made sure selector drum pimple operated switch so took out bulb holder yup no bulb must have used bulb for something else 🙄 I have been looking at the radiators and what will fit as I don't feel like putting my scabby old one back on. As there is quite a bit of info on rads are there any newer models to add to the list or Chinese ? I don't think I will be using the scabby tzr fairing when the whole bike is refurbed maybe tz late model which might fit a slightly wider rad ?

[SeaR1ck]

The oil line hoses are probably fine you just have to be careful with what your buying online. Had sellers try n pass off aquarium hoses.

As for the radiator and your using different fairing then stock. Go with the Chinese rad for the R1Z. It's bigger than the stock 1kt/2ma. The mounting points are the same as are the water pipe inlet outlet.

[biggz]

The pipes didn't melt, but were very badly routed - yours look much better - therefore kinked and guess what followed. Also the NLA grommet had hardened and the (fatter) clear pipes weren't happy. In all a very expensive corner cutting exercise.

L

[oldiggy]

Thanks for the heads up on the rad options,I'm back on it again after suffering more back issues , I've decided to fit old rad just to try engine first then will renew rad when stripdown. EGT sensors fitted to chambers filled up coolant 😬drip from pump housing coolant out again surfaces are good ithena gasket not wholly touching surface should have made my own re fit with a smear of 3 bond now ok I hate anti freeze on hands and tools need some dry days to run up engine outside.