Kawasaki KR1000 Endurance Replica

Exige said:
Soooo, a few updates to follow since the full strip down undertaken about 3 weeks ago due to a weep from the base gasket...
I double checked with the gasket supplier and they told me to fit it dry - note to self: never ever fit a base gasket dry again 🤷‍♂️

Engine ready to lift...


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I used cheap Tesco car mats to cover every bit of the fram which helped with a stress free removal...

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I fell for the fit it dry on a clutch casing gasket, it was my 650 Bandit, i went out for a ride and fuck me oil everywhere. I now always use a light smear of liquid gasket, Hylomar Blue is the dogs!!
 
Ger said:
I'm a big fan of three bond .....
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Very nearly used my 3 bond on the fuel caps before realising the grade I had wasn't fuel proof! I used Wellseal instead which another mate swears by who does bike restorations for customers.
 
I took the oppertunity to fit a cap in the top of the loom which was inaccessible until the strip.

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And stripped and re painted the cam cover using etch primer first this time, carb tops too...


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All back together ready to pop on Alan's Dyno for a leak check, carb balance and charging system check - a nervy day today 🥵


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Checked the filler caps a week ago and realised (as expected) the o-rings were less than ideal. In fact they shut off on the aluminium and didn't work at all.

So sorted some that worked:


Old o-ring...


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New o-ring...

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My mate Mark noticed the rough machine finish on the sealing face (that reminds me, he was making a side stand modification for my snazzy stand idea - I must remind him as it will soon have taken him longer than the bike took to build :unsure:)

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So that was polished out of both Caps...

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Fitted the Fuel Caps which seat onto the bare aluminium to prevent fumes seeping under the paint...


Gaskets cut for added robustness of the seal...


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There are 3 of these clamps per Cap so they were sealed with Wellseal too...


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All bolted in place (I then took each screw back out in turn and placed Wellseal on to the threads to prevent fumes running up them as a belt and braces...

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The threads on the Caps are a triple helix (if that's the correct description) so have 3 possible start points and are full down in half a turn. If I get the correct start point the Caps line up perfectly when fully down on the o-rings which is nice :)

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Breather hole was another likely fuel fume hot spot and some paint / lacquer had approached the edge of the hole under the paint mask...


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I had little room for error in removing it so glued some wet & dry onto a socket (trimmed it neater than this with a knife after the phot0)...

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And then gently fettled the troublesome bit...

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I am now just waiting for an aluminium spacer before I can finally fit the breather.
 
So today's run up was successful 🥳 no leaks, charging was spot on and carbs balanced up with no issue. And the engine sounded as sweet as a very sweet thing 🥰


I put the bike in the dining room when I returned home in readiness to fit the finished paint work over the next week so I can take much better side view shots as each part is fitted 📸


My painter messaged to say the seat unit (which has had the number plate tweaked on spacings) and the fairing should be done by tomorrow - but my Van is in for MOT so hopefully Friday will be pick up day (he's going to let me know if there's any delays so fingers crossed 👀 )



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Exige said:
Fitted the Fuel Caps which seat onto the bare aluminium to prevent fumes seeping under the paint...


Gaskets cut for added robustness of the seal...


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There are 3 of these clamps per Cap so they were sealed with Wellseal too...


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All bolted in place (I then took each screw back out in turn and placed Wellseal on to the threads to prevent fumes running up them as a belt and braces...

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The threads on the Caps are a triple helix (if that's the correct description) so have 3 possible start points and are full down in half a turn. If I get the correct start point the Caps line up perfectly when fully down on the o-rings which is nice :)

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Any ex RAF boys on here will probably remember PRC ? .....a two part fuel proof rubber sealant .....really good for a job like this ..the bloody times I could do with it nowadays ...... probably still made and has a civilian equivalent....🤔
 
Exige said:
Don't know what you mean? :unsure: Mrs Ex is not here until Easter and it will be on the road and living in the front garage with the other 3 that are on the road: do you remember them days :)
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Of mrs ex visiting me? She told me not to tell so pleading the 5th 🥷
 
Ger said:
Any ex RAF boys on here will probably remember PRC ? .....a two part fuel proof rubber sealant .....really good for a job like this ..the bloody times I could do with it nowadays ...... probably still made and has a civilian equivalent....🤔
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Not heard of that one but Wellseal was developed by Rolls Royce
 
Ger said:
Any ex RAF boys on here will probably remember PRC ? .....a two part fuel proof rubber sealant .....really good for a job like this ..the bloody times I could do with it nowadays ...... probably still made and has a civilian equivalent....🤔
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And it smells like dog shit !! :poop:
There's various varients for fuel tanks, panel sealing, aerodynamic sealing, etc all the same part numbers in civilian & military aircraft with varying cure times. PR1442B1/2 goes off in half an hour, PR1440B2 goes off in two hours, there PR1776 & a whole host of other numbers.
 
CAT3 said:
And it smells like dog shit !! :poop:
There's various varients for fuel tanks, panel sealing, aerodynamic sealing, etc all the same part numbers in civilian & military aircraft with varying cure times. PR1442B1/2 goes off in half an hour, PR1440B2 goes off in two hours, there PR1776 & a whole host of other numbers.
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Yeah ....the smell ......ha ha .......
 
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