TOPIC:

. The ultra low cap screws Daftrusty has used look perfect for the job, They are pretty much the same height as the original rivets.
Definitely going use them instead of button heads even if they didn't seem to foul on anything.
Also the 550 basket didnt have any gasket.
Haven't got much further on the dampers other than leaning towards using delrin.

On another note i have bought some Zx550 A1 cams and some new pistons and gaskets.

Be careful of using Delrin.
The data sheet says it has a maximum long term service temperature rating of 185° and can only survive short term temps of 300° and melts at 347°.
One hot summer day of creeping along in a traffic jam and they will either crumble or melt into the oil sump.
Plus, seeing as it is a solid/hard compound it will no dampening ability. So your clutch will no longer have any play but will also not have any cushioning ability. That will not make for pleasant drivability. It will literally shift with a BANG!

Hmmm reading the link that riturbo posted , Turbosteve who makes the viton versions mentions a guy in Tennessee who rebuilds lots of clutch baskets using delrin.
I also had a look at the data sheet and the low 185F continuous use stood out for me as well
At300F + i would be more worried about whats happening to the engine oil though.
Also theres still a set of dampers between the crankshaft and clutch

Im not totally sold on using delrin, but i don't mind a bit of NVH

I love the look of old race bikes so i started making some header slip joints from scrap pipe on the a spare head i have, .No 4 is a nice slide fit i just need to copy it three more times.
Also think i need to trim them down a bit so the flanges are closer to the head.

Its been awhile since i updated so I finally got the engine back together a while back Its now 615cc with zx550A cams and cv32 carbs. i had the head rebuilt and cylinder block bored by Ray Easson a well regarded motorcycle engine builder over here with many decades of motorcycle drag racing under his belt.

I Still need to sort out jetting but im extremely time poor at the moment with lots of weeks working away from home living in motel rooms

Have also done a 520 chain conversion



New Bitubo mono shock



Replaced the factory bars with some alloy renthal SBK bars. They are roughly the same height but slightly further forward .
I need to plug the fork ends as the original caps dont fit anymore


A

Looking good!

Nice progress!!!