New Build Project - KR-1 with 421 Athena Banshee motor.

[RickNC30]

Back to work...

New, shorter high tensile head studs fitted, head domes installed, all sealing O-rings held in place with silicone grease -



Head installed with refurbished water joint and new hose & clips -



VForce Four type reed cages with British made Showe reeds, 34mm carb adaptors -



First complete bolt together with PWK34 carbs and Ramair filters just to check that everything fits -



There`s still work to do - check squish clearances, shorten the inlet balance tube because the ends stick too far into the bigger carb rubbers, drill and tap those little bosses next to the chokes on the carb bodies and fit some kind of nozzles for the oil injection system - but overall it`s looking like an engine package that means business so I`ll probably be dragging the chassis back out of the corner next weekend...

[RickNC30]

As per the end of my last post, squish clearances have been checked by inserting the end of a suitably shaped length of 3mm soft solder into each side of the combustion chambers and turning the engine over - all good at 1.2-1.3mm. The brass fittings and sealing washers are ready for the carb mods -



The manifold balance pipe has been trimmed so it no longer intrudes into the inlet rubbers -



Those bosses on the carbs already have a cast in 3.9mm blind hole so I drilled that to 4.2 mm and tapped an M5 x 0.8 thread -



- then installed the brass hose fitting and using that as a drill guide bored a 2.5mm oil injection port through into the carb throat -



The `pull button` choke plungers will be replaced by cable operated ones when I get to the final build.

[RickNC30]

I found myself with an hour to spare last night so I thought I would bite the bullet and fit the completed engine to the rolling chassis.

Happily no real problems - the way the frame has been modified means that all I had to do was unbolt the detachable cradle, bolt that to the engine then put the whole assembly on to a jack platform and stand the chassis over it, raise it to the correct level and bolt everything back together again...

[JanBros]

nice

[RickNC30]

Footrests and controls next - when I built my last KR-1 I designed adaptor plates to use an FXCNC NC30 rearset kit on that bike so I`ve gone with the same set up again.



The brake side uses an FXCNC master cylinder with a built in piggyback reservoir which saves space, hydraulic brake light switch keeps that simple -



- luckily there is plenty of kickstart clearance so I didn`t have to worry about making up a folding footpeg arrangement -



Gear linkage uses a new RC30 front arm that was in my `it`ll come in handy one day` box and an industrial grade sealed rod end bearing at the rear. Prop stand has been lengthened a couple of inches to accommodate the bike`s taller than stock stance - everything has just the right amount of clearance and tucks away neatly -



The ZX-6R clutch lever that I was planning to use just wasn`t compatible and gave a horrible action with no feel so I have replaced it with the stock 350 YPVS assembly -



Looks all wrong mismatched with the silver lever on the Nissin master cylinder so I have ordered the black front brake lever from a 2013 GSX-R1000 to replace that.

I had five sets of those footrest adaptor plates made so I have a couple of sets spare if anyone needs them.

My fabricator is today making the jig and prototype for an aluminium version of the front fairing bracket - if there is any interest I will also have a batch of those made...

[pookie]

Project is looking great, now that the nights are drawing in here in the UK i'll be fettling more, I'm not that mechanically minded so I just fettle, not tinker, I like the ''It'll come in handy one day'' box, I've got a ''It'll come in handy one day'' loft! think there's half a Kr-1 up there keep up the good work.

[RickNC30]

Next job will be to fit these little beauties -



- another ebay bargain that I picked up a few years ago, shortly after I bought the modified frame - a brand new, still boxed pair of stainless steel JL expansion chambers made to fit a 350 YPVS with a Banshee motor, presumably from someone`s abandoned project as I picked them up for around £500. I`ve fitted Tyga mufflers, the same pipe/silencer combination that I used on my KR-1 project.

It looks as though they will fit pretty well despite being designed for the stock Yamaha chassis, main job will be to remove those hanging brackets from the tail pipes as there`s nothing on the KR chassis to connect them to. The only snag I can see at the moment is that the stand catches on the left chamber - it`s the spring hanger which causes the problem so I need to relocate the return spring on to the outside of the stand, cut that hanger off the inside and that should fix it...

[JanBros]

starting to look great