Carburettor

 

I have made the cables and fitted them in the carb - had one little problem though, when I was fitting the cables I dropped the thing on the floor. I expected to see the bell mouth out of shape or something broken, but fortunately everything looked ok, So now it’s bolted on the engine, and both cables have been adjusted, The carburettor that I fitted is a monobloc that I bought last winter and have run on the bike all thoughout the summer months, so I know it works ok, The old carb that I used to have fitted was a Concentric which worked with no problems but it was just the wrong type for the bike,      

You know when I said that everything looked ok after I dropped  the thing on the floor?  Well, it wasn't!  When I was taking the photos to put on the blog I saw that the throttle stop screw was bent. So, it looks like another item to go on the “to get list”.   

As my intention was to have the bike on the road for April 2011, and Christmas is just around the corner,  things will be slowing down a bit until the New Year.   And there are only a couple of things to do now; one is that I am waiting for a rocker box feed pipe, which is going to be made from a lump of billet;  and the other is I need to get two cables made.  Normally I make my own, but one is for the rear brake and the other is the clutch cable and as I don't like the DIY cable kits for this, I’d sooner get them made.  I am going to Kempton Park bike jumble in West London, on Saturday 4th Dec, if the weather is fine (like no snow - I do hate winters). The cable man should be there (and some other stallholders that I want to see).  I’ll let you know if I get any goodies! 

Choke Lever

 

Today the postman came with my choke lever (which I won on a well known auction website). I have been looking for one of these since owning my bike -the only thing wrong was it was a bit pricy! But I have one now so the one on the handlebars can come off. The difference between this one and a normal handlebar type lever is that the clamp on the back is hinged so it wraps around the frame (which is just over 1in ), and is held on with one nut & bolt. The hand lever was a bit too long for my liking so I swapped it with the one that I just took off the handlebars, which is much shorter in length and looks much better.

  

All that I have to do now is make a short choke cable and fit it to the carburettor. Oh yes, nearly forgot, I have to make the throttle cable too - then I can fit the carburettor. 

The Exhaust

 

I purchased this exhaust about six months ago from a well known company in the UK, so, no problem I thought. Well the first thing I did was to put some anti-blueing in the exhaust pipes - this is a product called kreem, which I think comes from the USA. I have used this before many years a go but it was a white colour then and it worked very well so I though I would use it again.

Now, this job should take no longer than around 45 minutes, but it wasn't to be. The exhaust pipes went on with no problem. But when I tried fitting the silencers, nothing wanted to fit. When I looked at the old silencer brackets they were an one inch longer than the new ones. After a couple of phone calls, and a chat with some friends, they all said the smaller ones were the right size. The thing was, the rear passenger footrest would not go over the silencer and through the hole that fixes them to the frame. Plus the hole was an inch lower and could not reach the hole in the frame. So, did i have the wrong silencers? Also, the exhaust pipes were supposed to have an upward bend on the ends, but they were the same as the old pipes that I had just taken off, and as I have had the new ones for six months and had put the anti-blueing stuff in the pipes, I could not send them back. So what I did was cleaned and painted the old brackets, made two quarter inch spacers on the lath to space out the silencers, and then fitted them.

Well they’re on and pretty straight, but I still think its the wrong exhaust.

Refitting the Primary & Clutch

 

Another day in the workshop fitting the clutch. As you will see from the pictures, it is a four spring clutch. So, first I put on the inner primary & the sliding plate, with the big felt washer behind it. Next, on went the engine sprocket, shock absorber spring, sleeve nut & split pin. Then I put on the clutch basket with new roller bearings. And then the retaining sleeve nut, which holds it all together. After that, was the primary chain.

After the chain went on, I put all the clutch plates in & new push rod which is a bit longer than the standard one, as I am putting a billet alley pressure plate on, which they say makes the clutch a lot easier to pull in & stops clutch drag. Also, when I fitted it I found that I could adjust the pressure plate a lot better  

So now, I have adjusted the clutch and primary chain and the outer cover is on, plus I have replaced the horn (as the old one was a 6volt aftermarket thingy, so I went out and found a refurbished one which is 12volt) from a bike show that i went to 

Ignition timing & top end

 

Today I moved one of my bikes from the bike shed & put it in my workshop for the winter layover, so I can give it a service & a good clean. This bike is a 2007 Royal Enfield 350cc trails, which is a road bike not a full fledged off roader, it’s just a fun bike to ride.

Anyway, back to the job in hand. I set the ignition timing on the A10 as per the Haynes manual, & rechecked it three times just to make sure it was right, but I will have to wait for the big start-up day to find out.

       

After setting the timing, I put the cylinder head on & fitted the rocker box. I used a push rod comb to set the rods in the right place, & as luck would have it, they went together the first time. I then adjusted the tappets to the correct distance, as in the book  

The Tin ware & Electrics

 

All done. I spent the day fitting the mudguards, oil tank, toolbox and chain guard.  I also put the wheels on and completely wired up the electrics. And as you can see from the pictures below, I have also taken the bike off the jack and put it on my lift.

 

The Electrics

All the wiring is done now. I bought a cloth harness with a white tracer running though it, instead of the black plastic one. Plus, I also converted the electrics to run on twelve volt instead of the normal six volt. To do this, all you have to do is take out the old dynamo chain and replace it with a belt drive kit, which makes the dynamo run faster, giving it a bit more on the output (it’s all to do with the size of the pulleys). Next job is to fit a twelve volt battery that I bought from Burlen Fuel Systems Ltd (which is their solid pure lead switchable 6 or 12 volt space age bike battery), plus a 12 volt regulator which is DVR2 switchable 6 or 12 volt from MTML and some 12 volt light bulbs. And there you have it.  Nice bright lights, so I can see where I am going - instead of those old dim ones.

 

 

This is the brown wiring diagram that I used, the reason being that most of the wires are brown with colour tracers.