Just a bit of an update really as Steve L has shamed me by starting later and finishing earlier
Here goes (photo or two will follow as soon as I can get some space round the bike).
Exhaust now fitted (bogstandard Im afraid but will certainly pass an MOT) I had to remove the isolastic type bushes from all of the mountings as they were absolutely US, and replaced them with some turned ali bushes. A bit stiff really but the hybrid has run with solid mountings for over 12 months now without any major issues.
Rear caliper now hopefully repaired, just waiting on seals to arrive. Someone drilled/tapped the inside half of the caliper with an M8 thread, obviously to remove a stubborn piston. The problem was it was drilled at an angle of about 15 degrees from vertical(a la Tower of Pisa) and not in the centre so after having removed M8 bolt and surrounding araldite I had to machine a hole in the middle of casting and counterbore on the inside. I then made a top hat type bung which was a press fit. Im hoping that this will hold the pressure. I will paint it tomorrow and hopefully get a photo of the repair.
Front brake pipes were 2 braided hoses directly from the mastercylinder one to each caliper. I find this arrangement causes the pipes to chafe more easily, so I have converted them back to a single hose from mastercylinder to an "L" shaped union under the headlamp, then separate hoses to the calipers from there. This is the same setup as original. I know there may be a little bit of loss of braking but the bike is overbraked on the front anyway.
I had to rebuild the wiring harness in the middle of the bike as there were about 10 cables that had gone virtually solid possibly from fuel vapours. This took me about 3 evenings to do but now I feel a bit more comfortable having done it. I havent checked it all as yet as I havent been able to get a battery as yet.
I think the slightly bent gearchange rod probably wont have much effect as I have assembled all the gearchange mechanism (apart from rubber boots over the rose joints) and it seems to change gear ok, only time will tell but I have a spare engine and box (which I knew was ok) to put in, but this really is a last resort.
Sprockets are both now fitted but front one needs tightening. I have used the original ratio for the 2NY 400 (14/41 with a 520 chain) I may have it wrong but I dont think it will be a disaster if I have. Im sure someone will tell me!!
I stripped/painted/rebuilt the Hagon shocks. There was an unusually long plastic top hat type piece that seated the spring at the top. The problem with this was that the spring rubbed it and it all looked a mess, so I made a replacement aluminium top hat that was a lot shorter and it def looks a lot better.
Jobs to do now include
Repair and paint chain guard.
Rebuild/fit carbs
Polish or paint the RH Engine cover (Yamaha casting painted black as I always do)
Rear Caliper to be painted/rebuilt/bled. Front to be just bled I hope.
Fuel taps to be cleaned/rebuilt etc
Few rubber hoses to be obtained/fitted
Oil and filter to be seen to
And that is it I think. Im sure there are a hundred and one more jobs that I will find along the way but there is a wee bit of light at the end of the tunnel now.
And YES It will be ridden once its completed/MOTd/Taxed
Ian
