Knackered's Project - Highly Modded Mk1

[knackeredMk1]

The original kickstart was shot so I bought an AR one. Although this was much lighter and in much better condition, I'm sure it was too long as the new tank comes a lot lower down the engine. I sold this as there seems to be a particular demand for kickstarts at the moment and have spent a few weeks looking around for alternatives.

I think I have found one - CR250 2003. It's in good condition, the splines fit and I think it's the right shape.

[knackeredMk1]

I knew someone would want a side view It's pretty well built

[knackeredMk1]

Having a real game with this. Took me 4 goes to get the glass fibre mould right and I've had 3 with carbon fibre Struggling
One is straight out the mould the others have been heavily worked on but nowhere near acceptable

[knackeredMk1]

Laid out the wiring loom so as to get some reference points before I start chopping.







No carpet jokes please

[knackeredMk1]

I have had a few rants before about the previous owners of this bike and I regret not taking photos before I stripped off the trully horrific stuff. This is the only remnant of the quality of workmanship. Rear light and number plate holder - cut shorter and drilled so it could be mounted on the bent subframe. The plastic burrs are still there but come away easily if you are so inclined. This was attached with a/f bolts (to knacker the threads) and cut with jagged ends (to knacker your hands).

[knackeredMk1]

Bled & fitted brakes last week + fitted seat - hopefully will anodise the seat fittings this week and get the engine powdercoated.

Going to rebore barrel to fit head and get new TRX piston. Stan Stephens cannot start new work until begining of July so looking at other options.

Have started chopping wiring loom to fit Vapor speedo - I really hope I get this right . Need to make surround to hold Vapor, indicators lights & switch for fan.

[knackeredMk1]

Fitted most of the plastics etc to work on alignment etc. Then took them off again to allow electrics, speedo, engine..... Anodising various fittings tomorrow.

[knackeredMk1]

Just for fun I thought I would break my project down by composition (based v. roughly on size & importance of parts):

CRM Mk1 23% (of which is original bike - 10% of the whole)
CR125 20%
CRM Mk2 20%
CRM AR 10%
XR650 10%
CRM Mk3 6%
KDX220 4%
CR500 3%
Transalp 1%
Other 3%

So it's still a Mk1 at heart

[knackeredMk1]

Having bought a Vapor Speedo I've succombed to getting the indicator surround as well - to neatly hold the idiot lights I need to make it road legal.

So I'll have speed, revs, air and water temps, clock, and lights, full beam, indicators and neutral lights ++++ all in one neat package.

Only thing is I'll have to reconnect the neutral switch I took off the loom a few weeks ago

[knackeredMk1]

New expansion chamber arrived today. I had a look at a DEP in a dealer but the welding was awful and the plating was so thin that bare metal showed through in a few places. I thought an FMF Gnarly would be better. Well the welding and the plating are better but the 'stretch marks' where the panels join are a bit grim (looks much worse than in the photo).

[knackeredMk1]

Engine back from Redditch Shotblasting . Barrel away getting rebored.

[knackeredMk1]

Oh Dear

I tried to fit the bearings in my crankcases today. Tried the 'freeze the bearings, bake the cases' trick. I knew I shouldn't do it - too tired.

Some dropped straight in, some required gentle taps.................unfortunately the gentle taps turned into panicked hits and then frustated wallops I'm afraid I lost my rag

4 busted bearings but i think the case is OK Find out tomorrow

[knackeredMk1]

In the light of the new day the crackcase and the bike seem to be OK

[knackeredMk1]

For the short term I have given up on carbon fibre . I really don't have the tools or the competence to make it work at the level I want it and I have spent sooooo much time on it.

I've managed to trace a new generator cover; this will suffice until I pick up the gauntlet again .

[knackeredMk1]

Started engine in today. Quite a way to go - clutch side, electrics and cylinder head has no studs. (Been on order for 6 weeks )