Current setup -

New smaller stainless steel ignition key and barrel to fit on new speedo bracket as have fitted XR400 yokes with the forks. I had to install the old Mk1 steering post on the new yokes as the XR post is slightly longer and doesn't fit. Much better length, sprung and damped than the CR forks.

Decided to revisit a Mugen head for my Mk1. So I have got the head modified to take the larger piston diameter and worked the head gasket so as not to get any 'hot spots' using the higher compression ratio. You can see the enlarged head capacity matching the head profile as a ring around the edge.



Works fine after changing the thermostat (which was no longer working ). Can't say there is any noticable gain in power but there should be a little at the bottom end at least.

Made a carbon fibre clutch cover -

I've changed the gearing by swapping some gears and the final drive shaft from a Mk3. Original Mk1 gearbox on the road with 17 inch wheels, 15 tooth front and 42 rear, 65 mph is ~6,5000 rpm (peak torque) and just a whiff of throttle. Not comfortable cruising or good for engine oil supply. Changing the top two gears to those from a Mk3 gives ~74mph at 6,500rpm.

I've actually swapped 3rd, 4th, 5th and 6th cogs together with the selector forks and final drive shaft but kept the 1st and 2nd from the Mk1 with the clutch shaft. I had to take 1.0mm thickness off the 6th gear cog on the clutch shaft and 0.5mm off one of the diameters on the final drive shaft to be able to fit the gears.

Wiseco TRX clutch basket fitted (work done by S. E. P. Kegworth) and 68.25mm rebore (264cc - 7.3% increased capacity from original) and Wiseco TRX 'Racer's' piston fitted.

Thanks, that was a good read.

Its a shame the photos don't work anymore, but I assume you still have them stored somewhere.

I think I'll start a rebuild thread for my mk3 soon, not a lot of action on here recently.