And finally, Wookie's 82 begins !

Had some mixed results today, I was hoping to get the carbs finished but alas it was not to be. "O" rings from Nessism, spot on - Choke plungers from Zed1015 spot on - then the Chinese shagged me  !!!!!!! I had the rubberised fuel tubes so bought some nice alloy ones on-line, the thought process being that I would replace the Chinese "O" rings with quality ones and all would be good however they "don't fit for shit" and need shortening (not the end of the world since I have a lathe but still a PITA  )

If anybody needs them this is the Suzuki part number for the throttle shaft seal

As I go through this build I try and apply everything I have learner here on KZR - something I was cautious off was tales of disappearing "choke rod detent balls and springs" I thought they would be easier to fit before "ganging" the carbs but wanted to be sure these small parts didn't fall out - my solution was to turn up these "keepers" which lock into place and hold the spring and ball in place until I fit the choke rod. When I push to rod through these will push out and leave everything as it should be. They only took a few minutes to make from the old alloy damper adjusting rods out of my front forks (I had to replace with longer ones when I extended the forks).

Last job for this weekend was to Cerekote the exhaust and airbox ends - turned out OK so happy with that

Wookie58 wrote:

 disappearing "choke rod detent balls and springs" I thought they would be easier to fit before "ganging" the carbs but wanted to be sure these small parts didn't fall out - my solution was to turn up these "keepers" which lock into place and hold the spring and ball in place

 

Great tip!
I'll have to try to remember this one.
I managed okay when doing a set of carbs, but this would help some more.

I managed to get these wrapped up today, fuel tubes shortened, Dynojet kit fitted, static sync done, float base settings done (will do clear tube before fitting). I also decided to make a mounting for the filter rather than having it flopping about on the hose. Still moving towards that light at the end of the tunnel

The light at the end of the tunnel is getting brighter as each weekend passes, that is the intake and exhaust complete now I'm really happy with how the exhaust has turned out - who would know it was "cobbled together in a shed" out of the remains of the original rusty Harris system that came with the bike, I reckon I have about $100 in materials in the exhaust so a bargain me thinks

Looking fantastic Guy, and that tunnel light gets brighter as summer approaches and the riding pleasure is about to start. 
Really have enjoyed reading your progress through this build. 
Rich.

That would be a winner-bike, everything and all are great work and results !!!

Moving on the last phase begins , I will get as much of the motor broken down as I can tomorrow (waiting for a rotor puller) no huge rush as my blaster is in Australia until the 18th March. I have switched in my stud/nut set-up but as expected not without issue. When I pulled the cam cover for clearance whilst I pulled the motor I noticed that there ere some "unusual" bolts in the cam caps !! I now know why. At some point somebody must have stripped the first part of the threads (this is what my stud set up avoids) then tapped the holes deeper and fitted longer bolts. You will see how deep the studs are sitting on the "modified" holes. These are 60mm studs so should have at least 10mm above the nut to accommodate releasing the spring pressure from the valve springs. The worst only has 3mm of clearance above the nut so I need to order 8x 70mm studs for re-assembly (will have to use clamps to remove tomorrow !!) None of the threads feel great so I guess I will be installing 16  6mm X2 helicoils . On the up side the cam lobes look really good so it must have at least had regular oil changes. Let's see what surprises tomorrow brings

Good insurance to helicoil all 16 holes.  I recently took my Z1 head to Harry's Machined Parts (my local motorcycle machine shop) because of 7 "loose" cam cap holes, we did all 16 just to be safe.

edit: And I'll be using long bolts with nuts to install caps, then swapping in the shorter bolts one by one even though the thread inserts won't be as likely to wear.

sf4t7 wrote:

Good insurance to helicoil all 16 holes.  I recently took my Z1 head to Harry's Machined Parts (my local motorcycle machine shop) because of 7 "loose" cam cap holes, we did all 16 just to be safe.

That's what I thought. Any that don't feel right will be addressed whilst it's apart. The last thing I want to do on a freshly build motor is thread repairs.