Finished at last!

Well here is the finished project!

This was taken at Cadwell Park Circuit on the Friday afternoon, for race reports/results and more photos plkease visit my other blog, (which can be accessed form this page).

On my way

Well Im on my way to Cadwell park for the first 2 rounds of the British Supermono Championship will post some photos and comments on my return

New blog

I am starting a new blog which will follow the antics of Ash Norrington #23 who will be contesting the 2009 British Supermono Cup aboard my Ymatax 640, I will post the build up to a race weekend and race results and comments, along with photos and videos. drbracing23.blogspot.com

Well the bike is almost complete and ready for her first race, its been a long and arduous project which just started out as a general clean up! this changed when I was asked if I would consider letting someone race it for me. Being the person I am I wanted the bike to be in a condition that I would be happy with, and that meant a lot of upgrades:

Replaced original forks with Yamaha R6 04

Upgraded FZR400 wheels to light weight TZ ally

Upgraded front brake to 320mm PFM disc and AP Racing 6 pot caliper

Fitted Brembo radial front master cylinder

New Vortex clip ons

Dennis Trollope rear sets

Upgraded rear shock to a Suzuki GSR600 K6

Upgraded rear caliper by using a Scooter front Brembo caliper

Fitted Yamaha TZ 250E Droopy seat

Powder coated frame,sub frame and swing arm

Fairing, seat, tank and hugger sprayed two pak

Engine was stripped, repaired and rebuilt by Steve Ruth

Aprox 100 hours of garage time by me

And the cost? Aprox £3k but had a lot of deals down the line so impossible to put an accurate figure.

Almost there

Just a few photos of the bike as it stands now. Just a few small things to sort out, ie rear caliper bracket and suspension set up then off to the dyno. Ash will be picking the bike up thia weekend to have the bracket professionally made. More photos to follow when all the decals are on it.

Engine is in!

I had a couple of hours before I went to my first job so I thought I would prepare the frame to accept the engine. But one thing lead to another and ended up getting the engine in! To my surprise in only took 30 minutes so was able to get a lot done.

The motor with Del Orto carb

Just a couple of photos of the engine and carb before it goes back into the frame.

Rear master cylinder bracket

When I was at Steve's last night with the engine a friend of his, Richard, was kind enough to give me a small piece of ally plate so I could fabricate the rear master cylinder bracket. Its a Brembo master cylinder and I would have liked to show the name off but it just wouldn't fit. It didn't have to be too elaborate and it only took the best part of an hour. As a short cut and to make it look "Pretty" I used some thick black vinyl to cover it.

Steve started on the engine at 17:30 last night, first thing he found was the clutch thrust washer behind the clutch was lifting the basket too high so the clutch lock tab had no spline to grip to, after sifting through a multitude of shims he managed to sort it. Next thing was the oil pump cog was impeding on the drive cog, again a small shim sorted that out. On the bottom of the left hand side casing is a threaded hole that you screw in a crankshaft stopper, Steve had been using this all night to hold the crank but when he put the capping bolt in it stripped the thread! Steve had to drill, tap and put a helicoil in, all this AND stopping all the swarf going into the engine. After about 40 minutes he managed to suceed.

The engine has landed!

That was the left hand side, (the clutch on the Rotax), done, next was the top end! This actually went on quite well but when he came to fit the cam pulley he noticed it was touching the casing behind, he read the manual and it said there should be a shim behind the pulley. Steve is very maticulous when it comes to engines and said there was not one there, so again a shim was found to sit behind the pulley, then when fitting the new timing belt he found it was a touch too long, with the tensioning adjuster at maximum the free play, (when the belt is pushed away from the guide), was over 10mm when it should a maximum of 6mm, Steve put the original belt back on. Steve then set up the tappet gaps and valve timing, which is way, way over my head! Steve tried to explain but my head was hurting....DOH. When Steve was bolting down the rocker covers one of the threads stripped, so yet again he had to drill, tap and insert a helicoil, however this was a blind hole so no worries about swarf. I asked Steve to fit one of the better flywheels, pick up and generator windings as the original was looking very second hand! And then at around 22:30 Steve said the words, "Thats it, its done!!"

I will be spending all my spare time in the garage now just to get this project finished, I have almost all the parts I need now so nothing can hold me back!!

Things are looking up!

I recieved an email from Natalee Wilds who I purchased the cases from a few months back, she knew what plate I was on about and apolgised for omitting it, said she would put it the post today so it should be with me Tuesday so I contacted Steve to tell him. An hour or so later I recieved a text from Steve saying he had found the plate we needed in another box, this is not the missing one but one that was in the boxes of spares I got from Dave Habel. I have arranged with Steve to go to his workshop on Tuesday evening with the bearing he needs and the timing belt, we intend to get the engine built if all goes to plan!
If we dont hit anymore snags Im looking to have the engine back in the frame on Weds night, Thursday evening I will get the exhausts, carb, cables and electrics all connected with the possibility of starting the bike on Friday afternoon. Should be able to get the bike to the dyno one afternoon the follwing week before travelling up to Cadwell Park next Friday for the first race.

Not looking good!

I received a call from Steve tonight with some bad news, the crank cases from my spare engine had to be machined out to accommodate the larger barrel, then Steve realised the cases did not have a breather. So the cases went back to his engineers who carried out the job there and then. But when Steve started putting the engine together he found a bearing retainer plate was missing! The original cases were slightly different and therefore could not be used. I have contacted the Company I got the cases from to see if they still have the part, but as its the bank Holiday weekend I doubt if I will get a reply before Tuesday! What with the extra expense of having the cases machined I have exceeded this months budget already and I have serious doubts to whether the bike will actually be ready for the first race in 2 weeks time, especially if we come across further snags.

Oh well chin up, catch you soon

seat is on!

Just a few photos of the sprayed seat in situ.

TZ Droopy seat

Picked up the sprayed TZ seat today from Thetford Finishing Ltd, as you can see Dave has done a grand job with the Two Pack paint. I was surprised how heavy the paint makes it, this was the lighter of the two seats that Ray from LRM Fibreglass had made me. He also called today to say the fairing is ready to pick up anytime I want so looking to collect it either Friday or Sunday.

The parts arrived for the Del Orto carb today and although its my birfday I crept into the garage and assembled the carb using the new seals, gaskets and jets.

Its a waiting game now!

I have ordered some new parts and a service kit for the Del Orto carb from Eurocarb Ltd and hopefully they should be with me in the next few days, so to be prepared for them I stripped and cleaned the carb. I would have liked to have had cleaned in the Ultrasonic cleaner which woulkd take time, something that I dont have a lot of. The bike needs to be race ready in just over two weeks and the motor still has to be built! DOH.
I also sprayed the exhausts after they were sand blasted by Nick, (BPS), just hope I can remember what pipe goes where?

I had fitted the longer rear brake line to the front while I was working out the caliper bracket so I changed the line for one that Ash had kindly donated, and to my surprise it only took about 15 minutes with rebleeding the system too, I must be geeting good.

Steve has said the engine will be ready for this weekend. I had to order another gear lever where the link arm is facing uppermost as the one I have impedes on the exhaust mount. Also picked up the repaired rear wheel from Abba ltd, they have done a fine job but alas the front wheel was too damaged to repair so Im on the look out for a TZ front 17" x 3.5" for the wets.

Ash will be taking the bike when its running to have the rear caliper mount made, hopefully he can turn it around pretty quick because I would really like to get the bike on the dyno before the first race just to see what the motor is kicking out.

My namesake in Indiana seems to have sorted his jetting problem but he wont know until he has a blast at his "Out Laws" place in the country, hope it goes to plan Dave.

It never rains!!

Just had a call from Steve, the guy that prepares my engines, he was heating the crankcases to fit the new bearings when he found one of the cases has a crack and cannot be used. He will have to use the cases from my spare motor but they will have to be machined out to accomodate the bigger barrel, so more expense but essential if the bike is to be ready for the first race at Cadwell, May 16th. Steve assured me it will be ready for next weekend, and as that is a bank holiday I aim to get the engine in and hopefully fire her up, then it will be down to the dyno to find out what the motor is capable of doing.

My namesake in Indiana, USA has also run into problems with the jetting on hi Yamaha 400 so if you can give him any words of advice check out his blob, http://davesfzr400.blogspot.com (click on the link from my site).

Ash at Snetterton

Ash Norrington, (my rider for 2009), was attending a track day on his Honda Fireblade at Snetterton so as I was working in the area I dropped by. He seemed quite comfortable on the bike even though he has not had much track time this year. All was going well until he decided to change groups so he was in the same as his 2009 team mate Andy Duncan, (Tigcraft Yamaha). Andy had already gone out onto the circuit when Ash arrived back with the amended wrist band and hastily got onto the circuit himself, I went to watch from Pit lane and on his first flying lap Ash was really motoring. As he went out of view into Riches Corner I looked back to see where Andy was, just then the red flags were waved and the session was called to a halt. As the riders came back in I could not see Ash! I waited a few minutes before strolling back and as I neared I could see the tell tale signs of mud and grass caught in the tyre wall. Ash was unhurt apart from a bashed knee and a slight headache, the bike was not badly damaged, just cosmetic but Ash said he was sticking to Mono's from now on!! Needless to say I did mention that if he done that to my bike there would be trouble!! he let out a nervous laugh.....

Just a quick update

I haven't had chance to do much on the bike this week but I have managed to sort a few things out! The 2nd gear from Rotax, Austria finally arrived this week so as soon as Steve gets back from his Easter break he can crack on with the engine, hopefully having it finished so it be be put back in next weekend. I also visited Ray of LRM Fibreglass to see what fairing would be better, I opted for the TZ250E which has a slightly wider front than the D, and Ray says it should be ready for me by the end of the week, however I may not have time to have it sprayed as it will need mounting when the engine and exhausts are in place in case of any alterations. The first meeting is at Cadwell Park, May 16th & 17th, then the following week at Angelsey, Ash has already said that he will not be doing this round as he will be unable to get time off work and the running costs will be coming out of one months budget. June sees the European Supermono Association racing at the British Superbike meeting at Snetterton, and if Ash is able to lose his novice vest he will be eligable to enter. I entered this race last year but came off at the Bombhole due to water running over the track, even so it is a prestigious event that can only be good for our class.

My name sake in Indiana, USA. has almost finished his Yamaha FZR400 and its looking the Dogs Swingers too, we have really hit it off yet we have never spoken,(something I intend to remedy in the near future!), and its uncanny how much alike we are, although Im sure he is a better rider than I was or ever will be!! I wish him the best in his racing.

TZ Droopy seat unit

I had purchased a TZ250E Droopy
seat unit from LRM Fibreglass several weeks ago and was very impressed with the quality, however in comparison to the original seat the new one was quite heavy. This was not a problem but I emailed Ray at LRM and expressed my views. I was not trying to get a discount or refund I just wanted to say that other makers of fairings and seats do not use as much glass and he may be able to cut the cost of manufature! Ray replied saying he was aware and as a gesture offered me another seat that is thinner FOC. I was gobsmacked that a company would offer this in the current climate and even offered to pay half, but Ray insisted that it will be gratis. Anyways I picked the seat up this morning and Ray explained that he had made it even thinner than he said, he has asked me to try it out and after drilling the mounting holes it was fitted in about 15 minutes, I had to make a few alterations, ie the oil filler cap is under the seat and it was a tad too long going towards the tank, but as you can see it looks the buisness. I have asked Ray for some LRM stickers as I will be more than happy to advertise his company as in this day and age there are not many firms that value their customers as much.

Starting to take shape

Well I managed to get into the garage and fabricate the front caliper bracket, Rob Hunt had kindly sent up a selection of wheel spacers so I could get the front wheel centralised. The making of the bracket turned out to be a tedious but rewarding job as the AP Racing 6 pot caliper and the 320mm dia PFM disc will stop a train me thinks. One downer to the day was when I positioned the other front wheel on the spindle I found that it was also buckled! so I have now 2 wheels that need straightening. I have been told they could be used but me being a perfectionist I want them to run true.

I was contacted recently by a guy from Indiana, USA and at first thought that it was an April fools joke, his name was Dave Bennett!! yes there is more than one of us, " Oh bugger" I hear you cry! he is also carrying out a bike rebuild, a Yamaha FZR400 that he intends to race, it also turns out we have a lot in common and he is a genuine guy that loves racing bikes so check out his blog: http://davesfzr400.blogspot.com/

I could not wait till Sunday to start on the bike so disappeared into the garage as soon as I had eaten. as you can see its actually looking like a bike again and its about bloody time too!! The work Steve's engineers had done was perfect and the forks and top yoke slipped on with ease an I also fitted the clip ons and levers, I must admit the Brembo front master cylinder looks the dogs swingers! I positioned the AP Racing front caliper where I think it should be and was amazed to see that the holes on the caliper and the holes on the forks are in a line, so a simplistic support bracket is all that is needed

Here we go at last!!!

Right! just picked up the fork yokes from Steve and I must admit the engineers Steve uses are first rate and the work looks spot on. Just to reiterate I had to have the bottom fork yokes milled out from 41mm to 43mm to accommodate the R6 forks, the top yoke did not have enough meat on the clamps to mill out so I used the CBR600 top yoke and the engineers have fitted a small bush in the centre hole,(where the spindle goes through), as the original TZR spindle is narrower than the CBR, I also had the clamps for the "Vortex" clip ons milled out too as I purchased them before I decided to upgrade the forks.

With the itch to start the rebuild getting unbearable and the first race looking ever closer I started rebuilding the bike in the garage, so I have decided to pass on the offer of James lock up as most of the hard work has been completed. I have contacted James to inform him and have offered my services when he gets back to the UK. I also managed to move a lot of the contents of the garage, (CRAP!!!), into the garden shed for the duration of the rebuild so I have gained a lot of space around the bike bench.

Not much happening

I seem to have come to a stalemate in the rebuild! Steve still has the fork yokes that are being bored out to 43mm, and without them I have come to a halt. I have been trying to space out the rear wheel but have hit a snag with the rear caliper mounting bracket, it just doesn't want to line up! Hugh Freeman was kind enough to send me another rear TZ wheel but when I positioned it on the bike I found it was slightly buckled, I will find out how bad when I fit some newer bearings to see if it is uasable. He also sent me a selection of rear sprockets saying they were "well used"! well after inspection I think I can "use them well" !!!! a big thankyou to you Hugh.
James Bensley got in contact about the lock up and Im now waiting to hear the word from his brother Richie as to when I can get in there, soon I hope. This will give me a lot more room to get all around the bike, I also spoke to Ash today and have asked if he could give me a hand on a couple of things, just think a fresh pair of eyes on the subject will help. I put the original FZR wheels on ebay and was happy to see them reach my lowest price, just waiting to see the final bid, I also put the Mikuni carb on there too after a mishap in the garage! I was looking at the carb to sort out jet sizes and gaskets when I dropped the bloody thing on the floor! when I picked it up I noticed the outlet track was broken. The carb was originally a 38mm but had been bored out to 40mm weakening the track. I contacted Allens Performance who informed me that they cannot supply that part so I have put it on Ebay and will at least get some money back. I will use the Del Orto 42mm carb that came with the bike, Steve gave me a carb mounted choke and the service kit from Euro Carbs is only about £12.50, plus a selction of jets are about £4 each, I have used Del Orto's in the past and had no problem with them.

Fairing bracket & Scitsu in place

I had ordered a new racing fuel cap from Ebay and was eager to see it on the tank, as you can see I went with the black to keep it in the colour scheme. I also fitted the front firing bracket and Scitsu tachometre just hope the pick up wire is long enough to reach the HT lead.

Shock is fitted

Managed to get into the garage today and get on with fitting the rear shock, as I mentioned before the dia of the spring is larger than the original item but not by much. I will have to shave a nikky whisker off the swing arm plate so the spring does not impede when compressed. When I put the shock in place I marked where I had to grind it back to, the shock was then removed and I set about the task with a drill extension and a small grinding wheel. I had given this job about two hours in my head but when I started I realised that it was not such a hard job and within 30 minutes I was ready to try the shock for size.

When I fitted the shock I was pleased to see the spring was well clear of the swing arm plate where I had ground it back, the next job was to space out the top fitment of the shock. After measuring the shock, then the gap I knew how much spacing was needed, this was done by using thick stainless washers and then everything was bolted tight. I let the preload right off so I could emulate the movement of the shock, and after several mimicked movements I was happy that the spring was clear.

Just a quick update

Just thought I would let you know how things are progressing: I managed to get a Suzuki K6 6oo/750 rear shock that fits almost perfectly, just got to shave a nicky whisker off the swing arm plate for the wider spring and space out the top mount, but it looks great,(photos to follow).
I dropped off the fork yokes and clip on brackets to Steve who is having them taken out to 43mm from 41mm, the original top yoke does not have that much meat around where the fork passes through but steve will let me know. But Ash gave me a CBR 600 top yoke which is 43mm and is the same spread as the TZR, the only thing that will need to be altered is the center hole, its just a tad too big so if Steve bores it out a little more I can fit a top hat spacer, so either way the forks should be in the bike by next weekend, fingers crossed! I also picked up the TZ wheels when I was at Steve's, and as they are in pretty good condition I can save some cash by not haveing them powder coated, just need a good clean.