Red: White Paint Test

Didn't get the warm weather I was hoping for, but it was just barely 60 degrees so decided to paint the tank to test the new Dupli-Color Engine White.

Setup the paint shop in front of the old trash door along with the two lamps.

The paint went on smoothly despite the cool weather.  It's a nice bright white.  Though after putting the tank back on the bike, there's something about the red/white contrast that could work.  Just need to play with what should be white and what should stay red.  Or do we still go with an all white bike?

Between coats, was examining the clutch parts in stock.  Realized that the drive gear and the plates from the automatic clutch are actually different than stock S90.  But in the old "X1" junk box, I actually found a good S90 drive gear and a few other knick-knacks.

Did steal the good friction plates, clutch cover, big springs, and small springs from the auto clutch.

Also unboxed the new eBay crankcase that I only bought because I thought I wouldn't be able to get the other case to work with the trochoid because of that knock pin problem.

Bottom End Build: Day Off Crankshaft Work

With a day off, decided to attack the crankshaft swap.  Needed to take the "good" one out of the display engine to use in the real bottom end.  I'd put the "bad" one into the display.

Here's why that crankshaft is a no-go:

• It has holes drilled into the flywheels which means it would throw off a stock motor.
• A standard piston pin doesn't fit through the connecting rod!!

The swap went relatively smoothly...

• Added the new woodruff key to the bad crank so I could fit the rotor.
• At first couldn't get the cases to close on the new case but just did it again (and a couple times more).  Just need to get the "feel".
• Installed both thrust washers on the good bottom end.
• Be conscious of the 2 thrust washers on the two sides of the kickstarter gear.
• Ran into a weird problem where I couldn't get the tranny to fit.  Need to make sure to turn the shift drum to full counter-clockwise before installing to set the gears in an optimal position.

Bottom End Build: Knocked Out

After doing a little research on removing knock pins, decided to give it a shot since with the knock pin in there, both case and pump were essentially useless.

YouTube videos suggest putting in a socket that fits inside the pin exactly, then using locking pliers to clamp down and twist it out.  Unfortunately, I didn't have a socket small enough to fit.  Decided to try it with a bolt instead, which didn't quite fit flush.

So the pin deformed quite a bit when I used the pliers, but I knew I was going to discard it anyway, so I had the luxury.

Lo and behold, just by continuing to twist it left and right, back and forth, it just slowly worked its way out.  Knock pin out, oil pump in, job done...

Bottom End Build: Trochoid Blues

Realized today that the trochoid pump I have won't work with the crankcase because the case seems to have a knock pin in the hole where the pump is supposed to fit - essentially making them both "male".