GT240 Build

[GeorgeS]

Hows this?

[HxPaul]

There's no kickstart fitted. The reference pin is at the bottom of its travel and won't go any lower.

If the reference pin is at the bottom of its travel and wont go any lower,but when the pin is removed the plunger goes further in,then it can only be the slot in the shaft thats stopping it.Therefore the slot needs elongating.

[Donnie]

Im pretty sure he is saying with the reference pin in or out, the plunger bottoms to the same level??

[GeorgeS]

Correct Donnie.

Sent from my SM-G920F using Tapatalk

[Donnie]

personally, yes, where the white paint is showing signs of rubbing, grind it a little, however is the kickstart piston actually rubbing the gears or not?

If not, I'd personally leave as is

[HxPaul]

If you look at the photos,it looks like the teeth of the pluger are lower without the pin than with it.

[GeorgeS]

I'll put it back together and have another check & extend the slot if needed (and grind a little of the shaft). The plunger wasn't catching on 1st gear, but the chaincase wasn't fully home because of this issue.

Thanks for your help here everyone, much appreciated. I'm sure I'll be back soon...
George.

[GeorgeS]

Everything has worked out ok. The first photo of the kickstart gives the impression the plunger isn't going all the way down but actually it's alright. It shouldn't matter that the pin doesn't make it all the way back to the end of the ramp, it's still doing its job regardless of this.

A little bit ground off the end of the shaft has taken care of it rubbing on the clutch, not much was needed.

I need to weld a bit on the kickstart lever so I can use a series 2 one on a series 3 chaincase (extend the stop), get a series 3 return spring as I see they're slightly different from the series 2 one that I've pinched (that explains why it doesn't fit well) and replace the kickstart seal that I've made a mess of.

Other than that it's almost ready to go. I'm hopeful for the top-end being ready in October, so could be a runner soon.

[GeorgeS]

The top end has now arrived so I can get working again with getting the last bits & pieces together.

So far I've not had a chance to do much other than soften up the edges of the ports (no other work planned on the barrel) and do a quick test fit. It was obvious that with the base packer fitted the squish was way off so I've removed that and we're about 1.45mm with just 1 base paper gasket. Everything turns over nice & smooth.

Here's a couple of shots of the top-end. I think Rich_T has done a small run of these, so you can contact him for more info if needed.






Need to order a flywheel and a few other little bits, so once that's arrived I can mark TDC and then fit it all together. I'll take some port timing readings over the next coupe of days.

Cheers,
George.

[garry inglis]

Why have you had to wait so long for this 200 kit I thought this was readily available