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Thread: BAB Racer to Cafe Racer

  1. #201
    MotoGP Star The Englishman's Avatar
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    Here the wear to the selector fork can be seen, it has worn past the wear pad and into the fork, no doubt there is wear to the gears and the side play clearances will have to be measured.

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    The selector drum is also removed.

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    I found this in the bottom of the engine, it's a gear tooth! I'll give the transmission an overhaul, I have two sets of selectors and 3 gear clusters for parts!

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    Next the crankcases are thoroughly cleaned ready for main bearing inspection.

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    During the visual inspection of the main bearings, I found damage to the shell bearings caused by hard particles getting past the oil filter (which was totally clogged) and passing through to the bearings.

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    Next, I used Plastigauge to determine the bearing clearance and serviceability of the crank and bearings.

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    Next post will be doing the Plastigauge check on the 'big end bearings', I use this process as part of my crank bearing check and measuring, I also use a micrometer to check the journal dimension and for ovality of the journal. I then use the information I have from both checks to determine my next course of action... My next post will cover this process.

    To be continued...
    Last edited by The Englishman; 09-17-2016 at 10:12 AM.
    Playing safe, is still playing!


  2. #202
    MotoGP Star The Englishman's Avatar
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    I did the clearance check on the big end bearings with the Plastigauge and did a visual check on the bearing shells, the wear is minimal, but there is scoring in a couple of the bearings from debris in the oil.. Here are a few photos.

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    I also checked the end float of the crank and side clearance between the con-rods and crank.

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    The next operation is to measure the crank with a micrometer for ovality, wear, and a dial gauge for run-out..

    To be continued...
    Playing safe, is still playing!


  3. #203
    MotoGP Star The Englishman's Avatar
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    The crank assembly was removed ready for measuring (tip: slacken the con-rod bearing cap bolts while the crank is sitting in the case), make a note of the Crankcase, crank and con-rod markings so that bearing identification and ordering is straight forward... In the case of this engine, there is either a mark or no mark on the crank case. crank and con-rods and the bearing shells are coded by 3 different color codes (not easy to identify on this engine!).

    First the con-rods were removed and marked and placed in bags for storage.

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    Next the main bearing journals were measured, two measurements were taken on each journal 90 degrees apart to check for ovality.

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    Next the crank pin/big end bearings were measured, again the measurement was taken in two places, 90 degrees apart.

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    The crank measurements are within spec and inside the service limits, however, the two outer mains have more wear than the 3 inner bearings and are at the outer spec. limit.. As this engine is going to be tuned, I will start searching for a better crank shaft assembly and as the con-rod piston pin bearings have some slight scoring, I will look out for a complete assembly in good condition... more to come on this!

    Once I find a better crank assembly, I will be balancing the crank, rods and pistons..

    Next I will be stripping the transmission apart, and building the best transmission I can out of the 3 transmissions I have.. I believe I have enough good parts for this

    If anyone is using Non-metric micrometers, calipers or dial gauges, just multiply the reading by 25.4 and you have your metric measurement..

    To be continued...
    Last edited by The Englishman; 09-17-2016 at 10:59 AM.
    Playing safe, is still playing!


  4. #204
    ........CEO........ .Cheetah.'s Avatar
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    This keeps getting better Keith. Really love seeing all the work you've put into it.

    Sent from my SM-G930P using Tapatalk

    2007 Honda 600RR / Will / CEO

  5. #205
    AMA Superbike Champ B-Rad's Avatar
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    Are u still up on that hill in corydon?
    I can only imagine the defining sound of the crickets keeping u company.

  6. #206
    MotoGP Star The Englishman's Avatar
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    Quote Originally Posted by B-Rad View Post
    Are u still up on that hill in corydon?
    I can only imagine the defining sound of the crickets keeping u company.
    Yes I am

    - - - Updated - - -

    Quote Originally Posted by .Cheetah. View Post
    This keeps getting better Keith. Really love seeing all the work you've put into it.

    Sent from my SM-G930P using Tapatalk
    Thanks Will, there's a lot to come, including frame mods, making a full tuned exhaust system and some serious engine work/tuning... I'm aiming to have it ready for next year's LSB trackday for some serious track time
    Last edited by The Englishman; 09-20-2016 at 11:01 PM.
    Playing safe, is still playing!


  7. #207
    MotoGP Star The Englishman's Avatar
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    Well, the weather is improving, so it's time I got moving on the old Kawasaki again.. Over the winter I've tried to source some high performance parts for the engine, but as one can imagine, there isn't a whole lot out there. However, there is a company who will rebuild, lighten and balance my crank and I have sourced some race camshafts... more to come on that.
    I will be starting the chassis modifications in the next few weeks, so I'll be posting on the progress for those who are interested
    Playing safe, is still playing!


  8. #208
    MotoGP Star The Englishman's Avatar
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    Well a whole year just shot by and I didn't do anything to the bike, but I will be doing some more work on it in the coming weeks... this bike deserves to run again lol
    Playing safe, is still playing!


  9. #209
    MotoGP Star The Englishman's Avatar
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    I'm still working on it lol tracking down some parts and messing with the engine and clutch options.. I will post up some pics soon... trying to save some money for crankshaft/rod work
    Playing safe, is still playing!


  10. #210
    Track Day Star c0al's Avatar
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    Quote Originally Posted by The Englishman View Post
    I'm still working on it lol tracking down some parts and messing with the engine and clutch options.. I will post up some pics soon... trying to save some money for crankshaft/rod work
    glad to hear it! I love watching this thread. So jealous of all the mechanical knowledge! I'll have some R6 front forks to be services over the winter, so maybe you can put that towards your crank
    2015 FZ07. Former Harley Davidson rider in recovery since 2015.

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