Start of the winter rebuild

[timbo]

Heard of plenum chambers, but had to google it to find out a bit more 
Every days a school day. Looking good Joolz

[JOOLZ]

Timbo they are especially important on single cylinder engines, you have to store the mixture from 3 strokes before the intake stroke happens, as the supercharger is pumping all the time. Idealy the plenum on a 600cc engine should hold 2400cc of mixture, unfortunatly I am limited by space so only have about 1400cc, not optimum but it should do

[JOOLZ]

Latest photos of my progress, Alternator spacer plate I made to allow the use of the xbr alternator with the xl600r cover and latest photo of the bike waiting for the camshaft and the plenum to be fitted

[attachment deleted by admin]

[JOOLZ]

Hooray the engine is finally reassembled thanks to the generous donation of a camshaft by Michael Moto63. The rocker cover fitting was interesting as the barrel is 4mm taller which meant there is even less room to manouver. The compression is 7.75:1 around what I was aiming for and should be a doddle to kick over, after all I have been used to 11:1+ for the past couple of years
I still have a few odd jobs to do, a cover for the top pulley also looking for a narrower top pulley, fix the belt guard, sort out the fuel and oil pipes
I have a friend who is coming over in 2 weeks time to weld up the plenum and after that I should be giving it a first start up.
Thanks to everyone for the help on alternitive parts and suggestions

[attachment deleted by admin]

[Moto63]

Great news Joolz, hopefully be able to hear it at some point and listen to that charger whistle. Best of luck with the first "fire up" ....
ps ....glad the camshaft worked out for ya.
Cheers, Michael

[JOOLZ]

Modfied top engine mount fitted and the fairing is back on and I am making a top pulley cover, all the electrics are now working. Still need to sort out a fuel tap, a belt tensioner and the belt cover

[attachment deleted by admin]

[JOOLZ]

Started thinking about jetting, I have done a rough calculation and recon the main jet will be about 440 up to 500. Jetting when naturally asperated is a 360

[JOOLZ]

I have fitted a the belt tensioner and fitted a new belt, Its going to need a bit of a tidy up to make it look better but it will do the job also fitted 8mm fuel pipes so it can flow more fuel

[attachment deleted by admin]

[JOOLZ]

Its almost finished, just completed the belt and pulley cover

[attachment deleted by admin]

[themoudie]

Tidy, Joolz. All the best when it comes to the start up.

My regards, Bill

[SteveC#222]

Looking good Joolz, Looking forward to seeing the beast in action.


Maybe you cpould give some hints to this guy....I think he needs it....

[guest2083]

This is very interesting, I'll look forward to seeing how it all works out.

[JOOLZ]

A few small delays and theething problems, the plenum i had made was warped during welding so the valve doesnt seat, I will have to face it with some emery and Im also having problems bleeding the oil system. These things are sent to try us but i will get there eventually

[JOOLZ]

Finally some progress, the plenum is now fitted, just got some final checks to do, refit the belt and cover then put the  tank and seat back on. Hopefully I will have a video up by this time next week This project has taken quite a bit longer than I anticipated and I have run into all sorts of unforseen problems. There have been a few times that I have doubts if I could do it or not

[attachment deleted by admin]

[timbo]

I wouldn't have the knowledge, cahonies, or shutzpah to even attempt anything approaching this kind of thing, so many congratulations, and thanks for consistently posting your exploits Joolz