Rare Japanese Market Kettle

[Suzsmokeyallan]

Thanks Malky I'll have to see if it shows up in the charts, I'm sure we would all like to be back a bit in time to roll back some years, and see the bikes when they were new, but 1976 ? hmmmm.
Roy thats great to see the B4 frame decal, now to get it off safely and have it reproduced. It would be good to get a straight on shot and a ruler against it as a measure it just in case the removal goes badly.

[oldjapanesebikes]

Roy thats great to see the B4 frame decal, now to get it off safely and have it reproduced. It would be good to get a straight on shot and a ruler against it as a measure it just in case the removal goes badly.

Good thought - you know, Reproduction Decals will usually give you a free copy of something they do not have if you can figure out a way to send them an original - the ones on the handlebars and the alarm light might be easy to ship to them. Just an idea.

[Suzsmokeyallan]

If you can get a little lacquer thinner behind a corner of those vinyl foil decals they will usually start to lift up. Doing this will allow you to work across the decals adhesive, applying more thinners as you go until its off.
If its in a place where the sun has baked it for a long time, chances are it will fall to bits once you start trying to lift it.

[tz375]

.........- isnt it a shame we cant travel back in time to 1976

No thanks. I did that once and made way too many mistakes since then. I have no desire to go back and repeat it all

[oldjapanesebikes]

I did that once and made way too many mistakes since then. I have no desire to go back and repeat it all

To quote Cook and Moore from the immortal 'Frog and Peach' routine - 'I've learned from my mistakes, and can repeat them exactly !'

[RING_DING]

Another Japanese decal....this time on the rear shock

[RING_DING]

Couple of questions for the forum:
1. The hose from the oil tank to the pump is pretty badly kinked from its routing under the pump cover (see pic). The hose is shot...any ideas for a replacement so it won't kink like this?
2. The banjo at the pump is pointing directly down (see other pic). I am planning to turn it horizontal just to test the oil feed and pump operation. Might be a dumb question, but I assume its OK to do this?
3. My plan to test pump operation is to attach a length of clear plastic hose to the pump banjo and fill it with oil. Then after bleeding the pump, mark the top level of the oil in the hose. Next (spark plugs out) I'll turn the motor over using the starter motor to see if the pump is working. Sound like a plan?

[malky]

Roy I dont like the look of that hose -the way its been kinked against the cover may have restricted the oil flow- I modified mine by drilling a hole in the back of the cover and filing it out to an oval shape which allows me to turn the banjo union sideways thus allowing the feed pipe to be connected directly without any danger of kinking it- I also used a piece of clear plastic tubeing in place of the black rubber from the tank to the pump inlet so I can keep an eye on the oil feed.
Mal.

[Suzsmokeyallan]

I used some clear tubing thats resistant to fuel and oil as well, then I filed open the slot in the cover on one side to change its angle slightly plus make sure it did not grip the hose in any way.
I then route the hose in a smooth arc so that its similar to the original but the clear tubing doesn't kink like rubber so its a non issue.

[RING_DING]

Malky & Allan,
Any chance you could post pics of your oil pump covers and the where you filed out the holes/slots for the tubing?
I bought some 3/16" clear fuel line but it kinks easily unless I turn the banjo horizontal. Any recommendations for clear tubing that does not kink?
Thanks!

[malky]

Roy - had a look at the bike earlier and cant really get a good pic of my mod as carbs etc are in the way but i drilled my cover in the centre of the back -if you look at your photo of the oil pump swivel the banjo union so that it points towards the left of the bike next to the gearbox breather - as for the clear tubing the stuff i used was truck screenwash pipe but you should get something similar from a pet store as i think they use it for tropical fish tanks for the air pump.
Mal

[tz375]

I have yet to find a hose that doesn't kink. They all do that sir....

Raise the angle of the feed banjo - that's a good idea and as someone mentioned, get a round file and open the clearance slot vertically to get a little more room.

Easiest was to check a pump IMHO is to fill the oil lines with one color of oil ab\nd then change the oil feed to a different color of oil., Run it and see if the oil changes color.

[Suzsmokeyallan]

Sorry for the delayed posting Roy, heres a photo of a modified cover with the bigger hole. You want to make it big enough so it just holds the hose but not squeezes it. Dont make it too big either as vibration from the cover will cut a groove into the hose.
I open up the top and right side of the existing hole so it maintains the same profile as the original, then radius the edges making sure there are no sharp sections.

[RING_DING]

Hi all,
Here are a couple of pics of the new oil feed line in place. I filed out the slot in the back of the cover as Allan suggested and I angled the banjo to make sure I had as smooth an arc as possible on the tube. I used Helix Racing Products 3/16" ID fuel line which actually feels a lot less kink-prone than some of the other plastic tubing I had experimented with.
Other updates:
* New air filter element (again SGP NOS) from these guys in the UK (excellent service by the way):
http://www.discountbikespares.co.uk/" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;
* Front brake rebuild kit (SGP NOS from Paul Miller) on the way.
* Fuel tank clean out with Evapo-Rust revealed a leaking seam on the left side. Would welcome any advice on how to deal with that. (I've read several posts recommending Caswells tank liner. Someone also recommended JB Weld for an external fix).
* Sprockets & chain are near end-of -life, so that will also have to be addressed.

The goal right now is to get her running to take part in a challenge that my brother has called for Spring 2012. This will be our second challenge event. The first was held in April this year and was a "650 challenge" (buy a bike for under $650, under 650cc and ride it 650 miles in a weekend). Six of us completed the challenge on various Japanese 4-strokes (mine was a Honda CB450SC Nighthawk which I resurrected from the dead). Being 2-strokers of old, our next challenge is a of course a "2-stroke" challenge (no limits on displacement, dollars or distance). By the way these challenges are usually concocted after copious consumption of malt beverages!

I am also hoping to get her down to the Gap for the 2-stroke weekend next May, so I look forward to meeting up with as many of you as will be there!

[RING_DING]

Synced the carbs today by the the method described in the Suzuki shop manual. Then I stuck my Morgan Carbtune on as a double check and I was amazed at how well balanced they were. Awesome!