Kawasaki KR1000 Endurance Replica
- Thread starter Exige
- Start date
Parts back today from vapour blasting... I left the seals in on the output shaft casing to protect the seal surfaces and need to pop in the new seals.
The fella at the blasters said they would be silk smooth anyway but going by the oil filter cover seating face he was wrong, so I'm glad I did. I will smooth the filter cover seating face with wet and dry using a small alloy sanding block...
The fella at the blasters said they would be silk smooth anyway but going by the oil filter cover seating face he was wrong, so I'm glad I did. I will smooth the filter cover seating face with wet and dry using a small alloy sanding block...
Had a trip to my mates for a final polish on the engine mounts using his buffing wheels earlier this evening. Two original mounts were chromed year ago and the two I made are A4 stainless. They match really well after the final buffing. 
the lower bracket and the one on the right in the picture are my hand sawn and power-filed items...
the lower bracket and the one on the right in the picture are my hand sawn and power-filed items...
Fitted the pistons & barrels today, but found out there was a small rubber block missing that holds the lower cam chain tensioner pin and alloy block in place between the top crank case and the barrels. Will need to order one, then lift the barrels about and inch to drop it in when I get one. I didn't remove one though so it must have been missing which now explains why the manual tensioner piston had deformed the old guide as it must have been vibrating causing it to melt and deform in the resulting 10mm gap allowing vertical movement 
So no cylinder head on as planned and no engine in the frame today
Pleased the barrels are on though as it ended up being a bloody fiddly job putting the pistons in first. Easy to get the rings in with no damage using finger tips but awkward to get the outer two pistons wrist pins lined up without the inner rings popping out again. My mate Mark was helping but it wasn't until another mate popped round who went on crank holding duty that we managed to get the outer ones on successfully. Having Teflon buttons helped greatly though rather than messing with circlips!
So no more progress until I get the lil rubber block...
Pub now to celebrate!
So no cylinder head on as planned and no engine in the frame today
Pleased the barrels are on though as it ended up being a bloody fiddly job putting the pistons in first. Easy to get the rings in with no damage using finger tips but awkward to get the outer two pistons wrist pins lined up without the inner rings popping out again. My mate Mark was helping but it wasn't until another mate popped round who went on crank holding duty that we managed to get the outer ones on successfully. Having Teflon buttons helped greatly though rather than messing with circlips!
So no more progress until I get the lil rubber block...
Pub now to celebrate!
Been out for 4 hours in the pub, while in the pub I realised I had a box of spares that came with a spare bottom end I bought about 4 years ago. Had a look when I got home and I have the missing part within 1 minute of looking
Isn’t beer brilliant
Isn’t beer brilliant
Doubt itCould this be the year you get to start it up ?
, the electrickery will be a limiting factor and some major surgery on the clutch pull mechanism to sort out - maybe next year eh? 
No point in rushing these things eh?Doubt it
How are thing's going with you and your Bros man?
All jokes aside, it is taking shape real good!!Slowly slowly
You still are a massive Guinness!!
Engine is kind of in
Need to do a bit of tweaking and double checking the engine alignment from the front sprocket. Waiting for some washers and a couple of stainless bolts that I forgot to order, but at least it's there or thereabouts!
Laid the engine on it's side on an old duvet and fitted the mounts while a couple of mates lowered the frame over...
Need to do a bit of tweaking and double checking the engine alignment from the front sprocket. Waiting for some washers and a couple of stainless bolts that I forgot to order, but at least it's there or thereabouts!
Laid the engine on it's side on an old duvet and fitted the mounts while a couple of mates lowered the frame over...
Last edited:
Shims dude, fucking shims not washersFrame is kind of in
Need to do a bit of tweaking and double checking the engine alignment from the front sprocket. Waiting for some washers and a couple of stainless bolts that I forgot to order, but at least it's there or thereabouts!
Laid the engine on it's side on an old duvet and fitted the mounts while a couple of mates lowered the frame over...
View attachment 50763
View attachment 50764
View attachment 50765
.
Washers sillyShims dude, fucking shims not washers
I'm pulling your chain dude, i have a NERO tv man!!Washers silly
Oh, I don't have a chain yet
Oh, I don't have a chain yet
Recommenced polishing the swing arm yesterday and today after a long sabbatical - now the engine is in its inspired me to get it done so I can get the bike on its feet.
This side is about where I want it, not too glossy and contrasts well with the bits left in a blast finish…
But this side needs a bit more
This side is about where I want it, not too glossy and contrasts well with the bits left in a blast finish…
But this side needs a bit more
It’s hard work, my poor fingers 🖐 isn’t it time you got hold of something to polishTart
needs a hole for his incontinent ways
They are for show and display, so Snap-On I guessAre they snap on or Halfords