Here is a novel idea, you could wait until I have the pieces to assemble the bottom end and see for yourself!


I believe I had a photo of my lightened flywheel in the old forum, sadly that flywheel has been damaged by external forces. Like me dumping something heavy on it and denting it.

It's time to resurrect this thread as things start to happen. I have been collecting parts, ordering more parts, and getting other parts fixed after the latest off. What will become the 'wet' bike is on stands in my friends garage ready for things to come off it, and the frame that will become the 'dry' bike has been scrubbed clean.


I should pick up my crank and cases at the weekend, all going well, but I have friends in from out of town. I'm hoping to get the bearings checked and order any new shells, before I go away on the 18th Dec. I have a list of things I want to finish before I go on holiday:
1. Check and order bearing shells for the crank (probably order new gearbox bearings too)
2. Assemble the frame and swing arm (new swing arm bearings coming)
3. Finish my new wiring loom (half done - made as per my wiring loom thread of a while ago to suit my xt-racing GPX lap timer)
4. Make the new dash to fit my xt racing laptimer/dash unit (i'll be relying on the LED's as the tacho from this point on)
5. Prep and hopefully paint my tail piece repairing the damage from my recent crash
6. Remove the parts from the 'wet' bike for mounting on the 'dry' bike (basically everything but the bottom end, wiring, and tacho)
7. Cylinder hone


The 'dry' bike will be as fresh as I can make it, with new bearings from top to bottom in all the improtant places, wheels, headstock, crank, swinger, and gear box. I get my pistons, new head stock, and piston rings when I go on my holiday. When I return on the 10th I will have until the end of Jan to assemble her!

Ordered a Barnett clutch and R&G crash bungs today for the forks and frame. Such a huge pile of bits all coming together nicely.

Didn't pick up my crank this weekend, but got cracking on the wiring loom, which si now 75% complete, all that is left is to wire in the XT raxing datalogger/dash unit.

I've started to shape my dash unit as well, effectively just rounding off an A5 piece of CF to act as a face plate. Word to the unwise, make sure you wear long sleeves, CF is even worse on the skin the glass fibre. Urgh.

Started to replace the bearings in the swing arm, and have hit a hitch. I can't get the damned needle roller to come out. Rotten sod of a thing. I shall have to muse on it at work tomorrow. My evening jobs next week are to repair a couple of trye warmers, finish wiring the loom, and finish the dash.

With luck by the end of next week all the parts will have arrived.

Right, this is a loom newly finished and unwrapped. I'll not wrap it until I have it fully plugged in on the bike and running. Stick coils aren't in the picture. I still have a few plugs to add, but I would rather leave those until it is on the bike and I can locate them properly. This loom has the pick ups wired in for the data logger/dash, but is essentially the same as the one I made earlier this year for the bike. Set up to run either HRC or STD CDI without fiddling around, just plug and go.


This is the almost finished dash. I've made a C/F sandwich. The dash is attached to the back piece, and I have cut a window out of a front piece. The window will be lined with some rubber bead, and I plan to place some foam and spacers between the two pieces of CF to tidy it up. The two LED's are oil and neutral and are bright as f*ck. I'll sure notice if my oil light comes on. I'll try and finish this off 100% on the weekend when I get to the spare bike.


Received my R&G crash bungs today, nice. I have a set for the frame and for the front forks. Very very nice. Just waiting for my barnett clutch and stainless bolts. Only things left to order are shell bearings, an input shaft bearing , head and clutch gaskets. I'm just hunting the best price.

I'm so f*cking furious right now. The needle roller bearing from the swing arm is now stuck half way out and simply won't move any further we've had it on presses, extractors, heated , you frigging name it it's stuck. And of course in the process it's completely f*cked.

Plus i've discovered that the replacement bearing I was sent is the wrong size. Brilliant. I'm about ready to chuck it in the bin.

Hell, what fun would it be if everything went as planned?!

These items are sent to test us. Other peoples incompetence will bring us down every time.


FWIW I've failed 'the test' several times.... &%#&*&!!

I've failed the test more than once. My girlfriends daewoo runabout has 2 knuckle sized dents in the bonnet from when I had to replace the water pump...

Anyways, thank god for friends of friends. A rescue call was placed and the swingarm went to a workshop in the early hours of this morning. The bearing shell was cut and it fell out nice'n'easy. Getting the new one in will hopefully be easier...

I'll be leaving that one in the freezer for a day or two before fitting for sure!

Ordered my crank and big end bearings today, as well as my head gasket and bottom end gasket set. Everything is in place, and when I come back with a suitcase full of parts on the 10th of Jan, will be able to go crazy. In the meantime I still need to paint my latest damage, and do some odds and ends to make life easier when I get back.

I'm so excited.

Hey, I have an NC23 (tri-arm) and want to rebuild the engine this Jan. Was thinking of putting the RVF pistons in like yourself. Did you need to use the connecting rods from a RVF and are the valve clearances differen't from the standard on an NC23? Also, were did you find all your gaskets. Found a few but not all, you don't know anywhere that does a full set do you?

I'm using standard nc29 rods. The valve clearances are also standard, although for racing and peace of mind I avoid setting them at the tighter end of the range. Ie if recommended at 0.12-0.18 I set at 0.18.


I haven't found a complete gasket set, but most sellers of 400 parts can supply complete head set and complete cases set. My gaskets came from RB racing in OZ.

thanks for your answers. one more thing, do you use low compression fuel?