Top end time then.
Again practice fit the barrels - I immobilised the centre pistons





I used 1/4" extension bars to hold the outer pistons





.... to give me this



After this I slapped on the head and tightened it using low, medium and then full torque. So next I'll move to cam shafts

Ace pics dude, great to see it. I rebuilding my klr engine. What number three bond did you use?

Coming on nicely .

ellow again

nice one boris, a good job well done

Wotcha :)

Dropped the cams in ... So cam timing then ... couldn't work out why it didn't go in right, until I read back through the manual and dropped the exhaust cam in first

TDC on the flywheel lines up with the cases joint at the front of the engine, and the cams marks are vertical on exhaust and vertical +15% on the inlet





With the engine buttoned up I moved on and used the new scissor jack to get the engine in the frame. Usually I drop the bike on it's side work the engine in and stand it up but using this was actually easier





Time for a well earned curry I think

More stuff done today, clutch in, generator on, exhaust & radiator on, oil & coolant in. I spun it over on the starter (it didn't go bang) to get oil pressure.
To do - put the carbs on, top the oil up, change the left hand clip-on. Start the bugger.

Looking good mate, nearly there ready for the summer.

Put the carbs and airbox on ... it runs


Woohoo

So after getting the bike to run I did a few small jobs, clean and set the chain, changed the brake pads for some EBC HH, I thwacked the lock stop boss around so the left bar doesn't trap your fingers.

Then I got onto the tail body panels, the left was a little scuffed but not to bad, I would have replaced them but I didn't see anything in reasonable knick. I decided to sort out the missing / broken bolt holes, the right hand one was worst so I cut a bit out of a scrap panel and let it in. The left just panel needed a bit moulded on.





Mot time and it passed. :)