1978 390 Auto build

Seems a bit complicated, fabricate cable holder, fix to engine sprocket guard, attach cable to top of foot brake lever, position on the lever will determine strength of braking.

I have already thought of that Steve. Kerry even dropped me over another rear brake lever to experiment on. The only thing I think about with that idea is it getting in the way of my boot ! I intend to try both mad schemes !
I am in the mood to think laterally tonight :-)

Great Idea, not sure about the 5mm play. If the 5mm play at the end of the lever then thats not bad.

Honda have made them for years, see what they do?

Had a good afternoon ! I collected the barrel from the re-bore .... had to go up a whole 1mm to get rid of the distortion.
Free time this evening, so managed to get barrel cleaned, studs in, gasket sorted, new Kawasaki small end bearing in.
Just putting the last wrist pin circlip in and ..... ping ! ..... off it goes across the workshop :-(
Spent 1/2 hour looking for it. Gave up, put kids to bed. Opened bottle of red wine. What would be your favourite expletive ....

rhymes with puck

BTDT
Years ago ....quick front sprocket change before a sunday ride with a cupla mates and Ping....ting (other side of shed) boing..(behind me somewhere??) and plink! (in the pile of parts!!) never found it, they went with out me...

Think i have about 20 spares, bought a bunch of parts for 80s bikes in 1 box of goodies. Had tons of cool parts. Even had 20 water pump snap rings and 5 new impellers.

what no O'Riliey's in roo land its a circlip 4 petes sake WTF

I hate that and have done the exact same thing!
Wait till you look for wrench for couple hours and it is right in front of you or it's in your back pocket.

I rekon there is a brain function that puts the shape of the tool you are looking for in your eyes but colors it with background! so that when you look at it, the shape covers it perfectly and you don't see it . you have to leave the shed and come back to refresh the shape and see that your missing tool is right where you looked 3 times ....! im sure!!

I like when you get to the shed and all of the sudden you can't remember what the hell you came in there for?????

dirt bikes must somehow affect the brain

Usually by the time I get to the house from the workshop I forget what I am there for and walk back to the barn to jog the memory again. Some of the above is why I am carefully looking when I am sweeping the shop floor

Moving on from the weekend issue ! .... good old HVA Factory to the rescue. A new pair of clips.
I found that the second clip did not seat correctly in the groove in the piston. I asked Andy to confirm the original dia of the wire used on the Wossner clip I had with the piston. They are 1.24 dia. I removed the piston tonight, checked the original one and that was spot on at 1.24 dia. Refit everything again (just to make sure I was not being stupid) along with one of the new clips. It still won't seat nicely in the groove. As they both fit perfectly on their own without the wrist pin they must be correct. The only thing I can think is the piston pin must be a couple of thou too long. Anyone else come across this issue ?
The pin came with the piston and is genuine Wossner. I like to be fussy about the internals of my engines.

Angle grinder attack on the gudgeon pin!!

That thought had crossed my mind Steve ! ..... but no :-)

Put it in drill press and use sanding block or real fine file followed by real fine sand paper?
Wrap pin in masking tape so you have a line to sand down to. Can't be much.
Also use masking tape around pin or copper tubing cut, so you don't mark up pin when tightening chuck?

i'd do it won't hurt a thang

yeah im not seeing how careful grinding of the pin would hurt.