All over the place...Maxim/Seca build

[Jeff0133]

This is how the shift forks should be when putting the tranny back in the lower case.Remember the circlips before putting the shafts in and of course assembly lube on the surfaces.

And then...

 

[Jeff0133]

Cases complete.

I was about to Button'em up when I realised that the assembly bolts were grimmy/greasy...So I Will have to do that before I put the case halves together cause all that work and cleaning would go out window if I was to put dirty bolts on there..
My OCD is acting up again...

 

[Jeff0133]

Did something stupid today, was left unsupervised with my Paypal account...

With this R6 rear shock AND my 20 inch progressive springs in front...Should make for interesting handling...

 

[OopsAboutThat]

Oh man, I've got an R6 monoshock on my bike right now as well. Had to modify the frame and swing arm quite a bit to get it to fit though. Not sure how yours is gonna fit seeing as it's looks to be a different year than the one I have. Good luck!

 

[Jeff0133]

Oh man, I've got an R6 monoshock on my bike right now as well. Had to modify the frame and swing arm quite a bit to get it to fit though. Not sure how yours is gonna fit seeing as it's looks to be a different year than the one I have. Good luck!

Not too worried about mods.I already converted my buddy's Seca monoshock into a Dualshock...
Did it improve your handling much?

 

[OopsAboutThat]

Wish I could give you some feedback, but I actually haven't got the chance to ride it with the R6 shock yet! Still working on getting it running

 

[Jeff0133]

Buttonned up the cases tonight.

Every bolt got snugged at first ...Then torqued to specs from manual, then rechecked 3 Times each.
Sealed the cases with this.

And finally put in a new oil Filter with new oring.
I got pretty cold in this here garage...So that's it for now.

 

[Jeff0133]

A little progress on the engine today.
Put the shift shaft assembly in , has to be in neutral position.

 

[Jeff0133]

Do not forget this little baffle.

 

[Jeff0133]

Cleaned, oiled, measured the oil pump,like new.
Changed the oring(black one on the right).

 

[Jeff0133]

Oil pump in with the oil pump drive gear.

And i put the clutch shaft on and the ball bearing at the end, I put assembly lube on the ball bearing so it could stay on place.

 

[Jeff0133]

Put the clutch boss in the the clutch basket with the friction plates that are all at 3mm so good news. Then bolted it all up. Remember to tighten the bolts on the clutch on an X patern

 

[Jeff0133]

Cleaned all the contact surfaces on the generator.
Cleaned the oil pressure switch.
Put the pick-up coils back in. they go in one way so easy.

 

[Jeff0133]

This Side is buttonned up.

The stainless hardware pops on the black paint

 

[Jeff0133]

Gave the cylinders a good hone.

The pistons will get new rings

 

[Jeff0133]

The pistons go on with the arrows on top pointing forward. Do yourself a favor and put the wristpin circlip that goes on the insides(facing the other piston) in before putting the piston on the rod and then push the wristpin in and the outside circlip last.
New gasket put in also.

Also put in the chain guide. Put in the tension rod and torqued to spec also

 

[Jeff0133]

Do not forget there are two dowels on the crank case, you can see where they go on the picture above. There are orings that go on the cylinders before you put them on the case.

 

[Jeff0133]

Put the cylinder on , a little tricky as some of the piston rings tend to hang while trying to push the cylinder down. This is how she sits now, put a ratchet on the crank to turn it over a couple times to see that everything turns as it should and that nothing hangs...All is good, feels tight.

 

[Jeff0133]

Now...The head.
First off, give the valves a good once-over because after soaking them in carb-cleaner, I thought they were pitted a bit but it was caked-on carbon.

Pretty clean.

 

[Jeff0133]

I wire-brushed the head...Not to polish but to take the carbon out, mostly in the exhaust ports. Then I noticed awfully big globs of residual metal from the casting process. So I took a burr to my drill to take some off...Not a porting job by any stretch of the imagination...But I really think it should reduce turbulences at the exhaust ports.