Electrics

Cut out the rot from the wiring loom and replaced with shiny new wires, paying particular attention to charging system which is relatively under-specced as standard on these single-phase alternator bikes.

Replaced all the rubber coolant hoses with plain black silicone and fresh hose clamps.

Front subframe and clocks mounted. Cleaned out the headlamp - they tend to get cloudy over time. Cleaned and checked the chain and sprockets - perfectly OK to re-use.

Filled with oil. Cleaned up the mess, fitted the sump plug and re-filled with oil....

Cleaned out the fuel pump mounting, gauze filter and the filter pot (which was full of the usual crud). New fuel filter, hoses and clamps fitted while it was easily done.

I had both UK and Euro headlamps, and couldn't see a difference externally though I had expected the glass lens to vary between left-dip and right-dip markets.

Intrigued, I took both apart and discovered the only difference is a small metal beam deflector which was easily modified so I now have two UK headlamps.

Roller

Forks fitted. Rear hub re-furbished and installed. Wheels in. Subframe on. Injection system mounted. Very few words required to describe what is a major milestone...the 916 is now a roller!

Forks, wheels, injection

Hub, sprocket, rear disk

Subframe powdercoated and mounted

Looks a bit like a bike...

Framed

Dropped frame over the engine and fitted swingarm, linkage and shock

 



Heads

Finally found time to prepare and build the heads. I had two full sets of rockers from which to select the best eight openers and eight closers, and almost enough opening and closing shims to get the clearances spot on, on the optimum settings.

 





Checking closers

 
 
 

Checking cam timing

Scrap

The 900SS crank was scrap, so I'm using the original 916 crank with new shells and rod bolts. Crank & rods have been assembled and installed into the cases, gear cluster and shift drum also, together with timing shaft. Thin coat of ThreeBond applied and the case bolts torqued up.

 

I spent a lot of time with a cup wire brush in the pillar drill cleaning all the fasteners & brackets before taking them down to the platers in Lancaster, where they've been given a coat of bright zinc plate with a yellow passivate. This photo makes them look a lot more green than they really are.

Shafts

End-float checked and adjusted on all shafts by changing the shims. Need to take another look at the crank I'm planning on using (a 68mm stroke item from a 900SS) because some eejit has mullered the end of it with a large persuader and it needs a trip to the crank grinder to see if it can still be used.

Bearings

New main bearings, gearbox bearings and timing shaft bearings fitted with the aid of a hot-air gun and the medium sized persuader.