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Project Progress / Re: The mighty BSA (BSA-Suzuki-Allsorts) thread
« Last post by themoudie on April 19, 2024, 03:12:29 PM »
Oh Ian! That looks a bl**dy awful (polite terminology) bit of "production engineering"!  :(

My only suggestion would be new left-handed drills to remove the remains of the studs, after soaking them with Bulldog BDX, having given them a good heating with a MAPX torch.

As for the sump drain plug, a pox on Yamaha!

I have gone off the idea of a SRV.

Good health, Bill
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Project Progress / Re: The mighty BSA (BSA-Suzuki-Allsorts) thread
« Last post by iansoady on April 19, 2024, 11:28:58 AM »
What a carry-n! I eventually managed to drill the head off the upper Allen screw but the bottom one was as hard as the bobs of hell. Eventually I resorted to a thin cutting disc in the Dremel and managed to cut the head off and release the exhaust.

This is what remains: a moot point as to how to remove the remains of the screws but I'll leave that for another day.



This is the offending sump plug from below:



This tries to show the exhaust in the way:



and this with the exhaust removed so I can get mole grips or if necessary a cold chisel onto it. Yes, I know.....




All this hassle because of a daft vacuum tap arrangement - although of course I would have been cganging the oil anyway.

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Project Progress / Re: The mighty BSA (BSA-Suzuki-Allsorts) thread
« Last post by iansoady on April 19, 2024, 09:29:50 AM »
I don't know what on earth those allen screws holding the exhaust on are made of but it took me nearly an hour to drill the head off the upper one and make a start on the lower one. It's particularly awkward as they're quite low and need to be attacked from a crouching position. Oddly enough the bolt holding the silencer to the exhaust came undone with little effort. Remember  the days when fasteners on Japanes bikes were as soft as butter?

I'm beginning to think the seller knew about these problems and passed them on to the first mug who came along. Although I did get it cheap (I thought....)
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Project Progress / Re: The mighty BSA (BSA-Suzuki-Allsorts) thread
« Last post by themoudie on April 18, 2024, 05:09:50 PM »
OOOOO, nasty! That sounds like a production engineers dream and a service manager's nightmare. The Boy Bros is like that in parts and only the reliability (fingers crossed ::) ) enable me to stay sane and for it to have passeed the 100K mile mark. Both SRX's required their exhaust studs renewing, as they snapped off in the head!  :( Stainless replacements and bronze nuts and washers, with lashings of copper grease on renewal. So far, so good.  ;)

I'll keep my fingers crossed for you.

Good health, Bill
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Project Progress / Re: The mighty BSA (BSA-Suzuki-Allsorts) thread
« Last post by iansoady on April 18, 2024, 09:11:51 AM »
So I'll bite the bullet and drill out the cap head screws holding the exhaust on. Fortunately there is a short curved section which actually bolts on to the rear head so I won't be risking breaking / stripping anything that would need access to that head as it's a pig to get to. Enthusiasm waning slightly.....
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Project Progress / Re: XBR Street Tracker - Moto63 style
« Last post by Moto63 on April 18, 2024, 06:50:31 AM »
Well... the levitating front mudguard no longer Levite’s. In the Knick of time I managed to bend and weld up 4 mudguard stays for it to nicely attach itself too. Just need a lick of black spray paint (which I don’t think I’ll get time to do before the show) then that’ll be another job ticked off the list.
Cheers, Michael
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Project Progress / Re: The mighty BSA (BSA-Suzuki-Allsorts) thread
« Last post by themoudie on April 17, 2024, 11:28:28 PM »
Aye Ian,

Quote
Bill - you may not want one after all. There may be a red one at a knockdown price soon.......
  :(

OH! Maybe I shoudn't lust after one, but I could be tempted as both Sally and the Monoshock were very disappointing after purchase.

Sally came home fine, with a ride up from Manchester to Perth and all was well with the world. That was until I went to start it the next morning and the rattle from the bore was like a flamenco dancer on speed, playing the castanets!  :(  So, engine strip, to find that the oil pick-up filter in the bottom of the sump and only accessible by splitting the crankcases, was half full of cotton fibres from using cotton waste to wipe up spills when changing the oil. Also, the oil pump seals (not a standard size and not available on their own!  >:( ) were hardened, so machined the seal seats to take standard size seals available off the shelf. 54K miles later the old bird started heavy breathing, but with no rattles and a cloud behind like a Bantam on overun.  :( 

The Monoshock came home from Aviemore, without a problem, apart from only having 14psi in the front tyre, until rectified and a new MoT, less than a week old. Next day started it up and after warming through the rumble from the nearside main bearing up to 3,500rpm was loud! The PO was on chemo and not expected to see the end of the year and I'm too soft ......  :-[  A tide mark through the engine at main bearing level, from condensation and similar faults as those seen in Sally's pick-up and oil pump, resulted in a £1K engine rebuild that I did myself, plus paintwork. To add insult to injury, I find the handling a bit "lardy" when compared to Sally or the Duke, it's those wide profile tyres.

Here's hoping Bertie Bassett proves a better purchase and that you can sort the SRV, without too much ado.

Good health, Bill
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Project Progress / Re: The mighty BSA (BSA-Suzuki-Allsorts) thread
« Last post by iansoady on April 17, 2024, 03:15:11 PM »
Giving up for the time being on the Yam. I thought if I could get the offside exhaust off I'd have more fiddle room but of course the allen screws holding it on are rusted solid and rounded off. I expect I'll have to drill them out. What other horrors await....

To partially restore my sanity and return this thread to its original topic I made a new clutch cable for the BSA. Very satisfying even though I'd ordered the wrong size inner and had to search my bag of spare cable bits to find the right one. At this rate it will be hitting the road before the Yam, which wasn't the plan.....
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Project Progress / Re: The mighty BSA (BSA-Suzuki-Allsorts) thread
« Last post by iansoady on April 17, 2024, 10:59:27 AM »
Well nobody said it would be easy....

I guessed that the petrol would have got into the cylinders so turned the engine over with the plugs out (by turning the back wheel in gear - I'm not daft enough to use the starter) and was rewarded(?) by a spurt of petrol from each plug hole. But if it's got into the cylinders then it must have got into the oil as well? So dive underneath only to find the sump plug has been cruelly hacked about. I'm starting to realise why the PO wanted shot of it.

Of course said plug is lurking between frame tubes and convoluted exhaust pipes so is a bugger to get at - no chance of stillsons or mole grips. I've left it alone for the time being while I ponder.

Bill - you may not want one after all. There may be a red one at a knockdown price soon.......
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Project Progress / Re: The mighty BSA (BSA-Suzuki-Allsorts) thread
« Last post by themoudie on April 16, 2024, 11:29:50 PM »
Aye Ian,

Have to say I am a wee bit green about the SRV, as I would like one.

The fuel taps sound the same as the SRX's and I have never had any problems with them.

However, if the float needle gets stuck and you come to a standstill at traffic lights, the fuel floods all over the hot engine and underslung exhaust pipe and the only way to stop the flow is to turn the engine "OFF" and hope that the whole lot doesn't ignite as it disappears in a cloud of vapourising fuel!  :o

Fortunately, I was able to turn Sally "OFF" and the vacuum tap worked, as there is no way unless you remove the two bolts at the rear of the fuel tank that you can get to the "ON/OFF" tap in the centre of the underside of the tank to turn that "OFF".

I hope that you are able to get the taps sorted to your liking and can enjoy a canter on the wee beastie.

Good health, Bill
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