Month: January 2011

I had the lamp housing powdercoated a while a go. The reflector brackets and reflectors are nos. Today I bought a standard aftermarket H4 lamp insert that fits quiet good. The difference is that there is an extra parking light so I have to rember this, when the bike will be rewired.

Received my K&N airfilter as replacement for the OEM airfilter.

After some basic cleaning on the cylinder I noticed some bad scuffs in the bore which almost look like they are the result of rust. I somehow have the feeling that even a rebore and oversize piston wouldn’t compensate – maybe a 0.8mm – but looking for a better cylinder and oversize piston seems to be the right thing to do right now.

I am currently stuck on the engine, because I need to buy a 36mm wrench for the sprocket gear, borrow a clutch holding tool, and ordering a puller with longer arms to get the starter sprag off the shaft.

Today I packed the left side engine covers and the handlebar so I can send them out for polishing / rechroming tomorrow. I also have two ugly seat pans which I will bring out for sand blasting and powder coating the upcoming week. I will use the pan that comes out better.

The piston was removed quickly.

It took me over an hour to get the cylinder of the studs as they were rusted like hell.

Well, I am no expert, but I am pretty sure this starter motor will not start any engine ever again. I am lucky that I bought a new one as replacement years ago, just because I got it for a good price. My replacement starter is the improved version which disengages when the engine fires back.

A NGK B8ES spark plug was installed. Dismounted oil return pipe and lower rocker cover.

Removing the starter sprockets

I drilled the broken pin out of the shaft which was easier than I thought. After that I removed the chain cover.

I    

Removing coils plate.

I removed the clutch hub and plates with my selfmade tool.

A colleague lent me an extractor that worked getting the rotor lose. But somehow I am confused about the shaft, isn’t it supposed to have a notch and a key? Somehow this looks strange. I also learned the hard (hurting way) that it is better to leave the center nut loose on the main shaft when pulling the rotor.

I removed the oilpipe, the intake rocker cover, tappet covers and flange cover

As I am stuck on the left side of the engine as I need to buy or borrow a proper extractor to get the alternator rotor off I turned the engine and trying my luck on the right side. Removed clutch cover, circuit breaker cover, oilstick and speedo shaft.

Then again, I am stuck as I need a proper tool for removing the clutch.

A power wrench did the trick of removing the nut from the alternator (turn to right to open!)

Today I drained the engine oil removed some of the clutch parts and cleaned some parts. I then noticed the kickstart shaft already has some broken out teeth. I have to find a replacement for it.

Some more pictures from removing alternator cover…

I removed the alternator case cover. The case screws are 6 mm x 18 mm (Inbus).

Today I received some dellorto spare parts and so I could finish the work on the carb. The air filter housing is also ready but I do not have a air filter and I do not have the parts required for connecting the air filter housing to the carb. I would bie happy if someone could tell me part numbers?

Is this the correct handlebar for a SS-350? I am not sure where I  have it from, it could be from a Z90 as well and I want to be sure before I send it out for chrome plating.

After more than 2 years in which I didn’t have the time to work on my bikes, I have decided that I will continue with the SS-350. Well, actually I still do not have a lot of time left as there is still a lot of more important work to do, but I am going to take the time!
I took the carb, disassembled it and cleaned it with the ultra sonic bath and some “DREMEL polishing” and the result is not too bad. The carb was very dirty all over but not damaged as far as I can tell. I have already ordered a few new screws and new gaskets which are still available.

Notes:

• Metering Pin: V10
• Low Speed Jet: 45
• Main Nozzle: 265T /(125)
• Starting Jet: 70

That seat pan is nothing more than rust. I will trash it and look for a better one.

Almost a rolling basket in Februar 2008

• Disassembling the front fork
• Polishing the front fork. Left side “after” and on the right side “before”
• Redone front fork
• Rear wheel and front fork back in frame

   

The wheels are total makeovers. New aluminium rims, new stainless steel spokes. Hubs are polished to shine again and brake shoes are sand blasted. New ball bearings and seals and new Dunlop K82 tires. I also decided for a 19″ instead of a 18″ front wheel.

The guy who already painted all my other bikes also repainted the gas tank for the SS350. When he sent me the gas tank it was totally damaged by transport and had to be done again. The decals are reproductions made by myself.

The whole frame and a lot of smaller parts are now powder coated. 
I started reassembling with a new steering lock, new ball bearing for the front fork and new turn signals.

The naked frame ready for powder coating and an engine waiting for restoration. The engine is heavy like a rock, so why are people calling these bikes lightweight Harleys?

 

My new motorcycle lift. Never thought I really needed one, but it makes working on bikes much more fun.

First pile of parts after powder coating