Author Topic: Project Assembly  (Read 18681 times)

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Ji Gantor

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Re: Project Assembly
« Reply #90 on: May 24, 2009, 08:39:13 am »
And now there are two air box struts.

Looking good.


Ji

Ji Gantor

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Re: Project Assembly
« Reply #91 on: May 24, 2009, 06:05:02 pm »
To install the motor the swingarm has to be connected.
So today we start with all the major parts ready to go.

Ji

Ji Gantor

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Re: Project Assembly
« Reply #92 on: May 24, 2009, 06:07:50 pm »
First grease the brass swingarm bush. Make sure you fill all the gallerys.

Ji

Ji Gantor

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Re: Project Assembly
« Reply #93 on: May 24, 2009, 06:10:13 pm »
Grease and install the bearing inner rings into the swingarm.

Ji

Ji Gantor

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Re: Project Assembly
« Reply #94 on: May 24, 2009, 06:12:45 pm »
Install all 4 "O" rings.

Ji

Ji Gantor

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Re: Project Assembly
« Reply #95 on: May 24, 2009, 06:14:55 pm »
Grease the chassis swingarm tubes.

Ji

Ji Gantor

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Re: Project Assembly
« Reply #96 on: May 24, 2009, 06:17:25 pm »
Grease the engine mount tube.
Use anti-seize grease.

Ji

Ji Gantor

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Re: Project Assembly
« Reply #97 on: May 24, 2009, 06:19:58 pm »
Grease the pivot pin and place it just inside the chassis tube.

Ji

Ji Gantor

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Re: Project Assembly
« Reply #98 on: May 24, 2009, 06:24:57 pm »
With the dividing washers in place install the engine mount into the chassis.
I found it easier to install the engine mount into the swingarm away from the frame and then slide it into place. The "O" rings are hard to compress while installing the dividing washers.

Ji
« Last Edit: May 24, 2009, 09:32:59 pm by Ji Gantor »

Ji Gantor

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Re: Project Assembly
« Reply #99 on: May 24, 2009, 06:29:42 pm »
Position the lock washers and install the end cap bolts.
I have installed the cap bolt with the grease nipple on the wrong side because it was easy to take photos of it that way. The grease nipple needs to be on the other side or the rear brake rod will clash with it.
I have secured the lock washers with S/S safety wire.
Connect a grease gun and fill the cavity inside the pivot pin until it runs out the opposite cap bolt threaded area.

Ji
« Last Edit: May 24, 2009, 06:31:59 pm by Ji Gantor »

Offline jimg1au

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Re: Project Assembly
« Reply #100 on: May 24, 2009, 06:33:29 pm »
ji
my cz400 has the bolts drilled so you lock wire the bolts no way they are coming off then
keep it coming
jim
cz400 1972
cz250 1973
both projects

Ji Gantor

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Re: Project Assembly
« Reply #101 on: May 24, 2009, 06:34:44 pm »
Install the shoocks.
Loctite the shock mount bolts or use a new spring washer. I did both.

Ji

Ji Gantor

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Re: Project Assembly
« Reply #102 on: May 24, 2009, 06:41:38 pm »
Next I have to fit the engine so place the chassis on a piece of carpet on the floor.
Wrap some Ableflex around the chassis rails where the paint may get damaged if the engine drops.
I placed a section of 10mm thick nylon onto of the bottom rails just in case, ply would have worked as well.
I taped the engine mounts so I did not take any paint off as the engine was slid into place.
Have another person help guide the engine into the mounts and install the bolts while you hold the engine.

Ji
« Last Edit: May 24, 2009, 09:36:21 pm by Ji Gantor »

Ji Gantor

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Re: Project Assembly
« Reply #103 on: May 24, 2009, 06:44:26 pm »
So the rear guard can to fitted the seat has to be in place.
The new plastic seat pan needs to have connection plates installed.

Ji

Ji Gantor

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Re: Project Assembly
« Reply #104 on: May 24, 2009, 06:46:44 pm »
This is what the original front seat pan connection looks like.

Ji