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Third time

Wow... I didn't realise awesome could get more awesome... love your work! :D
 
The frame and the engine has taken apart. I have cut some old fasteners from the subframe and painted the whole frame with VHT`s Roll Bar satin black paint.

I have examined the cylinder head and the exhaust valve guides are out of the tolerances.
I was lucky to make some good e*ay deals. I got new over size valves (24mm ex and 28,5mm in), titanium spring collars and Kibblewhite valve guides in good price.
Next week I need to take the cylinder head with new parts to the machine shop.
Then I need to open the cylinder bores in the engine block.
I have ordered all new transmission ball bearings and the crankshaft ball bearing.
So far all looks good to get the bike finished before summer...
 
Opened the upper engine case for the bigger cylinder block. It takes about three hours with air die grinder. Now there is at least .004" gap between sleeves and case.
Is that enough?

2013-01-02190200_zps9a72ee96.jpg
 
Definitely gives all us builders something to strive for. I love it
 
As said several times, if can't get better, but it did. A rolling billboard for quality.
 
I cleaned and inspected the clutch basket (V&H billet) and found it had more wear in 3000 km`s than original
clutch basket in 100 000 km`s. I need to check it again after few 1000 km`s.

2013-02-02175658_zps5ae47835.jpg
 
That basket don't look so great. I've read here (but have no personal experience) about how some of the "extra plate" clutch kits have skinny fingers that do that to the basket. I think Suzuki had a similar problem too, in 1983 or something like this. At any rate, Rapidray or blowerbike (Terry) would know for sure. I know just enough about that sort of stuff to be dangerous.

Project is awe inspiring. Please keep going and post up lots of photos.

Oh, and love the new tank shape. Awesome!
 
I get the cylinder head from machine shop today. Now there are new 24mm exhaust valves with new Kibblewhite guides, intake valves and seats are machined and head is skimmed 0.2 mm. The compression ratio is now 9.3:1. It?s not much, but with some boost it should be ok.
 
The cylinder head is assembled and installed. The intake camshaft is now 112.5 lcl and exhaust 113.5 lcl, so the lsa is 113 degrees.
 
I'm going to need photographic proof ;)

Cylinder head with valves, etc.:

2013-02-10150019_zpsb0cc5e5d.jpg


I spend a long day in the garage today. It was mostly installing all parts in the frame,
but there was many small things to do ie. all new fuel lines, some fasteners, where to put fuel filter, etc.

In the end of the day:
2013-02-11170527_zps42777d90.jpg


Before that I tested how the finished seat fits to the tank and tail:
2013-02-11190547_zps84651282.jpg
 
The big day is closer! Nearly all electrics done except tail ( rear light, brake light and blinkers ) and license plate light.
To do list is: new aluminum front fender, fuel tank final pressure test, finishing the fuel tank & tail, license plate holder and some small things.
Today, when I get my old laptop to communicate with updated Megasuirt and get some basic things adjusted, I sprayed brake cleaner in
the plenum and pushed the start button... it runs with 2 or 3 cylinders a few turns!
I think next to do is finishing the fuel system and get the bike started!

2013-03-02173529_zpsc67c9581.jpg
 
Wow that's looking awesome! I love the "Scream" mouth on the turbo pipe there. Is that a blow-off valve or something? I'm not really familiar with turbo's...
 
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