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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Thu Jul 11, 2013 9:03 am 
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Joined: Mon Jan 21, 2013 4:36 pm
Posts: 180
the pressure plate pushes the posts which moves the plate at the rear off the pack. the springs push back against the hub.


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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Thu Jul 11, 2013 9:59 am 
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Joined: Thu Oct 14, 2010 11:23 am
Posts: 1122
Yes, they bottom out on the six posts; do not over-torque, the springs keep pressure on this all the time. Without the pressure plate and springs installed you should have at least 1/8th-inch clearance between the outside surface of the top disc and the inner side of the big circle clip. Once everything is installed that will go away and it will be too tight to push by hand. MikeV


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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Fri Jul 12, 2013 7:04 am 
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Joined: Sun Jan 09, 2011 1:26 am
Posts: 175
Images: 6
Location: Melbourne, Australia
;) Thanks Brad & MikeV,
superb info & knowledge.
I must have loosened the pressure plate bolts slightly before I took the photos, so that is what confused me.
After talking to a chap at work, he too suggested the plate needs to bottom out on the posts and the bolts torqued up to only 10Nm. Otherwise, it's off at the post!
You are correct MikeV, the clutch assembly cannot be moved by hand. When I assembled the clutch pack, 2 steel discs were slightly tight to slide along the splines. The hub shows no signs of notching as does the basket. So, I filed them ever so slightly and now they slide along the splines nicely. I thought I needed to do this so the clutch discs didn't drag. I oiled the friction plates and discs. All good.

I will be putting up some photo's of the engine build shortly.

I'm so close now. I just wish I had more time during the day!
Cheers,
Steve

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"...Honey, it's only a project bike...."


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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Thu Aug 22, 2013 5:02 pm 
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Joined: Sun Jan 09, 2011 1:26 am
Posts: 175
Images: 6
Location: Melbourne, Australia
Gents,
I'm close, very close to firing the engine up for the first time in a long time. However, I need some photos showing the wiring and cabling routes.
I've checked out Carlo's website under restorations, but not all the images show the path of the cables & wiring.

Can anybody assist here please?

Thanks,
Steve

P.S. I have taken photo's of the build thus far. I just haven't had the time to load them up. And, I'm on a war path to finish it.

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"...Honey, it's only a project bike...."


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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Thu Aug 22, 2013 7:09 pm 
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Joined: Sun Nov 07, 2010 10:54 pm
Posts: 425
Location: Brisbane
Hello Steve,

Correct or not, this is what I did,,,,,

From the throttle, both cables aim down and curve back up then the front cable goes between the steering head and the right fork into the cut out in the tank and onto the front carb. The rear cable goes into the cutout in the left side of the tank then over the top of the frame cross brace (where the top of the shock is attached) then down to the rear carb.
The clutch (mine is hydraulic) goes from the lever to the right of the steering head then between the top frame and tank, over the top cross brace then down to the clutch. You may have to look at another way if you have a cable clutch.

Graeme


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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Fri Aug 23, 2013 9:40 am 
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Joined: Sun Jan 09, 2011 1:26 am
Posts: 175
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Location: Melbourne, Australia
;) Sir Graeme,
That, my good man is perfectly explained!
Could you take a shot of your wiring plate at the front to show your routing please?
The main concentration of wires are up the front, so their length doesn't have to be long. I'm modifying a standard Bosch terminal block wiring harness so that it is shorter and set out as shown in previous pages...somewhere.
I'm waiting on my local engineering firm to modify the standard Pantah swing arm jaws so I can assembly the rear end.
The main focus is getting the engine fired up.....hopefully, not literally!
Thanks again Graeme.
Cheers,
Steve

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"...Honey, it's only a project bike...."


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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Fri Aug 23, 2013 6:26 pm 
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Joined: Sun Nov 07, 2010 10:54 pm
Posts: 425
Location: Brisbane
Mine is Kokisan from a '95 not Bosch so it will be not what you are looking for.
If its of any help I can send a picture, just ask.

Graeme


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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Fri Sep 13, 2013 3:02 am 
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Joined: Sun Jan 09, 2011 1:26 am
Posts: 175
Images: 6
Location: Melbourne, Australia
:geek: Folks,
it's almost there...

Engine photos will be here shortly. Suffice to say, when one is nearing completion...everything starts to fall apart. Well, not everything, but the little important things....

Anyway, we'll start off with the pre-assembled engine installed...
Attachment:
Assembly12.jpg
Assembly12.jpg [ 251.81 KiB | Viewed 215 times ]

Other side....
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Assembly14.jpg
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Oooh, that's a bit close...what happened there....
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Assembly15.jpg
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Dremel them!
Attachment:
Assembly16.jpg
Assembly16.jpg [ 115.17 KiB | Viewed 215 times ]


More to come...

_________________
"...Honey, it's only a project bike...."


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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Fri Sep 13, 2013 3:09 am 
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Joined: Sun Jan 09, 2011 1:26 am
Posts: 175
Images: 6
Location: Melbourne, Australia
:geek: continued...
Ahh, cleaned up the little 36's...
Attachment:
Assembly17.jpg
Assembly17.jpg [ 184 KiB | Viewed 215 times ]

Rear 36...ohh, damn it close again...see the bell mouth slightly bent.... :twisted:
Attachment:
Assembly18.jpg
Assembly18.jpg [ 181.12 KiB | Viewed 215 times ]

Ahhh, the jaws came back from the machine shoppe...
Attachment:
Assembly19.jpg
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Well....let's go crazy!
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Assembly20.jpg
Assembly20.jpg [ 357.38 KiB | Viewed 215 times ]

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Assembly21.jpg
Assembly21.jpg [ 219.34 KiB | Viewed 215 times ]

Attachment:
Assembly155.jpg
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Assembly154.jpg
Assembly154.jpg [ 201.84 KiB | Viewed 215 times ]

Attachment:
Assembly22.jpg
Assembly22.jpg [ 190.51 KiB | Viewed 215 times ]


Now, we just need a throttle....
Cheers,
Steve

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"...Honey, it's only a project bike...."


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 Post subject: Re: Aussie TT2 track bike build
PostPosted: Fri Sep 13, 2013 3:51 am 
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Joined: Sun Nov 07, 2010 10:54 pm
Posts: 425
Location: Brisbane
Looking Good!
The last 5% takes 90% of the time,,,,,,,,,


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