Well 3 weeks have passed and I've made pretty solid progress. I have the new solenoid in and wired up properly. I started on the front brakes, the caliper was was fine but the master cylinder was filthy with old brown crud. I tried cleaning it out but it wasn't enough so I pulled it fully apart. I damaged the rubber boot in the process so I ordered a K&L rebuild kit. When it arrived the piston was too big! but the rubber part was the right size so I cleaned up the old one and got it all back together.
Then I took the forks apart for the now seals. That all went pretty well, the hardest part is removing the allen bolts. then it took a bit of head scratching to figure out the assembly order but got that sorted too. So the front end is all back together. I added brake fluid and got reasonable pressure in the brakes but not 100% yet. I also checked & re greased the wheel bearings too. I also did the same to the back wheel, got that back together & tensioned the belt etc. For the electrics, I ordered an el-cheapo headlight just to get it going and I got a replacement lens for the broken one. So the headlight wiring was pretty straight forward. I checked in a new 'LED' flasher relay and all the electrics work perfectly. I drained out the oil, fitted the new filter & filled her up again with my favourite oil.
I had been thinking for a while how I was going to create a new air filter. I bought some UNI filter sheet and cut 4 pieces to fit. Then I folded some 25x1 Aluminium flat to make some holders for the filter element which I held together with duct tape. It turned out pretty tidy, see photo below. I got a new battery on Saturday and chucked that in too. So by Saturday evening I had her ready for the resurrection maiden voyage...
The idle hangs a bit but not too bad so I took her down to a large empty carpark to do a few laps and see how she runs. The answer is well pretty shit! It was going ok, all the gears shift nice and smooth and the clutch is good. Front brakes were a bit mushy and may the pads have fluid on them... back brake was good for a drum. Eventually she died & I couldn't get her going again so I pushed her home. First one that hasn't made it home! Turns out that a lot of flaky rust had clogged the petcock and the in-line filter (glad I added that!) so I cleaned those out sloshed around the tank a bit & poured some fuel out of the tank so most of the crud should be outta there by now. Remember my petcock hat no filter tubes!!! Some dick took them off??? I ordered a new petcock today, a fairly generic aftermarket one with no vacuum set up. Guess I have to plug that hole too... So I got fuel back in the bowl and got it running again last night. I checked the fuel levels they are both at around 10mm so look too low, I'll check the manual and set that correctly. I also checked for vacuum leaks but didn't get any obvious rise in RPM from spraying carb cleaner on the holders.
So my challenge now is to get rid of the hanging idle. when I rev it, it does drop down but too slowly. The problem with my air filter is I don't know how much air is getting through compared to the stock set up. Any ideas on that one?
I can also check the valve clearances but I'm pretty sure carbs are my issue. Annoyingly I think my carbs are 'US model' that has the welch plugs over the air screws. I know how to get them out but still a PITA and the are in an awkward position for adjusting.
So first I'll set the fuel level and see what that does, then welch plugs out so I can adjust the mixture etc and then try what ever anyone else suggests...
Cheers, Hama