oil pumps, master cylinders and spuds

Lately there has been some 3ma’s in the local ads so between myself an mick we have been trying to get a few parts together.

Turns out that mick has a spare wonky pump, that i could have for parts, great except i though mine was a differnt early pump.

Well i was wrong, there was just an extra bit of the pump stuck in the case, my pump is completely normal and it could be swapped for a 3xv one, sorted.

Bloody runner is acting up again, broke the 90* bend coming out of the top of the carb, it’s still leaking from the base gasket, the idle screw i think is still too short (26.abit mm from tip to end of threaded section) and my attempt to lengthen it failed from a dodgy aldi/lidi tap, and all the 6mm fuel lines are cracked. And it’s still drinking fuel.

The bajaj has been going well, here is the cbr6 14mm master cylinder and lever chucked onto it, the lever is very nice but it don’t fit 🙁

This is a kawasaki zrx400 rear master cylinder, 1/2″ or 12.7mm (top one in pic) much easier to mount, possibly the wrong size but we shall see soon, i’ve already paid the 100€ for hard lines and flexible hose’s to fit it all up, don’t have the pic of the final bit of welding to mount the master cylinder but it’s done. Just need rear brake lights and a few more wires soon.

Karen, a true irish cat wondering “where’s the spuds?”

Stuff done.

Well started fine tuning the runners jetting.

My pwk 24mm carb has:

Needle          JJH

Main jet        110

pilot              40

slide              3.1mm  tough to measure this

float height  18.8

Air Screw     2 turns out

The pilot is way too rich, at quarter throttle it’s four-stroking like mad and quarter throttle is from 0-80kmh, couldn’t find a 38 jet online so got a 36, may have to put the air screw out one turn, rather then an optimal 1.5, but with a 36 i should be able to get at least an idle.

Also found an injection kit which seems to be built on microsquirt, very interested.

Not much done to the bajaj, tried to get the drum off to check the brakes, didn’t wanna come, so i assume i need a proper diagram of how the front is supposed to come off or it’s rusted on. Got the wheel changed tho.

Busa tank is ready so got started on the fairing, rear posts for the light needed trimming but no other faults yet.

Nice ain’t it? you can see the hump paint don’t match.

Runner 180 Kart airbox

Well heres how it looked the other day.

Ended up putting back on the front mudguard , doesn’t suit the massive rear tail and i need that tail since i don’t want a wet arse.

More bits left over.

And this is where i left it to go to the..

..Munster 100! i sponsored a bail for that you know! this suzuki 250 below won the classic.

This suzook was some where down the field.

What the feck is a tsr250?

NomNom

Anyways after the neighbour ciaran won the 650 race (passed him once on a track day) i got back to finishing the runner.

First up was to remove the superglue from the inlet, it was already cracked, but only on the outside. cheapy poo.

Then while i had some epoxy out i fixed up sarges old bandit cover, which will be handy for the gsxf track bike.

My modded kickstart got modded again back to standard so it wouldn’t hit the new airbox, with all the pies cut out of it it’s a bit shorter now, and i have to stand behind it to kick it properly again but at least i have a choke now.

The articule, very light, but beginning to think it really needs a big spring or rubber band to hold the airbox in place rather then the single bolt at the rear, very vibey these things so i’m not gonna be very surprised when that little tab at the back breaks.

How does it go? bloody well, needed to raise the needle for more fuel and what goes with more fuel? more air! the engine is getting more air then when it was just a filter, job done.

well i still have to run it in a bit more and then do proper flat out testing and jetting before it’s really job done. also i’ve scored a pm tuning head with slighty dodgey spark plug threads and the handling is still rubbish. so really not job done i suppose.

Runner 180 kart airbox

Made a thick adaptor to fit the airbox’s filter

Then with some fiddling about it’s pretty close to fitting, still had to use the heat gun to get some clearance around the rear tyre and a little bit more around the shock for good measure too.

Cardboard mock up of the brace, didn’t get any photos of it done in steel, needs another bit to give it full strength. Nice spot to put the number plate if i get rid of the rear splash guard. It looks a bit too wide but it goes no further then the passenger peg or the kick start.

The mudguard that was attached to the engine is gone, can’t be bothered cutting it up to suit, and it does feck all anyway

As you can see in the last pic, it should fit with out body mods, and it sounds perfect,just a hint of induction roar, will have to get the new job done, get the body work on and go for a proper test ride.

i can just get to the kickstart, mines modded to be a bit higher, but now i have a working choke with the oko so a standard lever would be ok now.

the runner the rxs and the tzr

Many updates today.

link pipe for the runner 180/kart airbox experiment has turned up, just have to dig the runner out now..

Got started on sorting the rxs fork. after some measureing i’l be taking 4cm off the length.

picture to remind me how to put them back together.

tzr gearchange lever needed lengthening to suit the aftermarket rearsets.

scrap paper calculations.

scrap metal for the chop

magnet holds it all together quite nicely while i weld.

20mm increase on the long part and 5mm on the short part, there should be no difference in lever throw and i can now change with my foot rather then my big toe nail.

then i sat around looking at this r6, i did not measure the front end to see if it would fit the cbr6….

Kart airbox, runner 180

well the airbox turned up, massive ain’t it?

got a free kart steering wheel cover as well, now if i just had a car to attach it to…

me thinks i have to attack the airbox with a heat gun to make it fit, and also probably get a filter with a straight neck.

there are so many thing i have that just need a little bit more work to finish off, i’ll never get anything finished in true timmy style..

Runner 180, kart airbox

Busa looking well!

rxs100 head badly modified to fit a rx135 barrel, may have a go at the rxs again soon.

oko pwk carb with filter on that doesn’t fit.

if the tyre was new…

test spin! nothing fell off anyway, didn’t open her up, needs more running in, the noise from that filter is unacceptable.

it rubbed, su-fuckin-prized?

think i’ll make it fit the bajaj.

So i’ve ordered a lamellar kart airbox from superkart.it, they had excellent dimensions. should be here in two weeks (back ordered)

http://www.superkart.it/index.php?main_page=document_general_info&cPath=149_176&products_id=1146

this one was also considered, bit its a little odd shaped.

http://www.superkart.it/index.php?main_page=document_general_info&cPath=149_176&products_id=1145

this one is suposed to be best but i can’t find any dimensions

http://www.superkart.it/index.php?main_page=product_info&products_id=1600&language=en

 

Runner ready? ish…

Anyone remember this?

Well it’s been put to a good use:

fecking awesome no?

then i had to ride this thing around a bit to check it’s all working after a rebuild. all good,some more gearbox oil and then have to do a bit more testing tomorrow to make sure it’s good for competition.

Got further along with the runner 180, glued in the autolube nipple, nipple it self is rescued from the old delorto. Last time i did this i glued it in with epoxy this time it’s only held in by superglue, we shall see how that turns out.

must protrude into the fuel/air stream.

Top end complete, never checked the whole barrel height after murphy engineering skimmed it, but it only took one 0.4 gasket to make the squish 0.9, the base gasket should have been 1.0 along with the corresponding hike in the ports. it’s still an improvement over standard just a small one.

cable length for the PWK is next hurdle. and i have to buy bbq paint.

Skipping the solid engine mounts for now, lets just get it started first.

Parts are here!

and well bloody wrapped they are.

PWK copy 24mm, look at the meat left over, could bore that out at a later date.

We now have three rs250’s dotted about the house…

Racing rs125, it’s actually so nice, stuff the rotax 257 in it and it would be a dream.

We have a new dog: Busa. he’s a whippet and in quite a bad state. Nothing 114 euros worth of pills and injection can’t sort.

The pictures don’t show much, he’s got mange, scabies, pressure sores (we hope!) and his tail looks like it might have to go. If your brave here are some before pics :

https://picasaweb.google.com/maireadomullane/MyNewDog# in a months time there should be some much better after pics.

 

In other news, i upgraded the laptop to ubuntu 11.04, holy shit it’s useless, what the hell is it these days with replacing simple text with unintelligible icons? i know it a beta and all that but i can’t stand it, didn’t mind when canonical first swapped the window management buttons around it was actually a good idea grouping more of your controls in the upper left of the screen, but this is jump in the wrong direction. So all my computers are finally debian now.

 

Why a runner blows up.

The root cause was the water pump not being turned any more, weather it was the bolts falling out of the oil pump causing the wheel not to engage the pump or the wheel wearing out then the bolts falling off the oil pump I’m not sure which happened first. Parts are on the way anyway from http://www.psntuning.co.uk/ should be here next week.

rotax 123 barrel on runner 180 cases? i wish

Inlet envy..

I Will get this thing rolling tomorrow, i must!

In anticipation of fiddling with the carb i’ve put back in the standard 15.5g (i think there that weight anyway) rollers, slower ratio changes make it easier to diagnose problems.

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