I managed to repair the BMW switches

I managed to repair the BMW switches - it's a little like microsurgery with spring loaded ball bearings and contact plates - but that gave me a good solution to the problem I had with finding switches and levers that looked like they belonged.

There seems to be an abundance of wires for such a little bike. I can see another challenge coming on.

Well, I picked up the barrel today - gloss black 2 pack with polished edges on the fins. Looks nice, there's an incentive to get the motor finished. Just the camshaft re-hardening and the same with the valve ends and it's ready for assembly. The cam is a second hand unit with nearly 13mm of lift. I'm not sure whether there is enough room with a 10.5:1 piston yet. I'll measure it up as I turn over by hand before I go too far.

A bit of time on Australia Day saw the clutch and kickstart refitted and the side cover put on - albeit temporarily as there is further polishing to be done. It all looked good, so I put the barrel and head on, without the piston, just to see how it looks with a bit of bling.

The motor is now installed in the frame, but quite a lot had to happen to get it to that stage. I had the original cases polished and all the engine mounting hardware chrome plated at Chrome Masters so the pretty bits were all done. The camshaft came back from Tighe engineering (503 grind) and was refitted with a new chain and guides ($$$!!!). I fitted my elephant foot tappets, but they didn't allow enough clearance and advice from the Yamaha 500 Forum said that I needed to grind 4mm off the rocker arm to give that clearance. That sounded like a recipe for disaster, so I bought a pair of the KEDO ball end adjusters and fitted them

yesterday.Today I finished all the seals and gaskets and put everything back where it belongs, then put the motor back in the frame.

That bunch of wires referred to as "The Electrics" is my next target. No easy fix there, I'm going to have to do some pruning I think, or get a bigger headlight shell to fit all the connectors into. Perhaps the long winter evenings will allow for a bit of re-design work. I've added to my bike list too - a Ducati ST2 - so the last of the good weather is being used for riding 2 of my 3 bikes while not working enough on this one.

It's a long time since anything was added. The motor has been removed and refitted a couple of times because I have put gearbox shims back incorrectly, leading to tight shafts and vague gear selection. It's all fixed now, but after splitting the cases 4 times in total, I'm a bit over looking at the inside of the box!

I have fitted an alloy swingarm, which went in easily and really looks the part, and a set of Ceriani forks which will hopefully make the front end a little more compliant - whatever happens, they look good.

I'm still fiddling with wiring and switches, but I feel like I should be sacrificing chickens at the full moon rather than picking my way through 1 wire at a time. I've got a pair of XT 600s to get running and sell as well as this one, so it's busy in the shed!

I found a stainless rear guard from Motolanna in Thailand. It is a one piece unit rather than a plastic / steel combo like the present setup, so I will cut that and mount it to get the right look when it arrives. I think the guards will be a gloss charcoal or black, as there is already enough chrome and polished alloy to keep a solar power supplier happy. The rear brake pedal is going to have to be fabricated and added to the rearset peg - using a shortened footbrake lever with the existing fittings is looking pretty untidy. Not sure how I'm going to incorporate a folding peg with the lever yet.