Originally Posted by jjrider

How are you planning to press the crank back together perfectly lined up with each other, it is critical in pretty much every aspect to be aligned, not just straight. I've seen plates with the shape of the crank hubs for the top and bottom of the press so both halves are trued when they go together. I'd love to setup for doing these, be easy to do stroker cranks then !

Originally Posted by Provick

Kind of surprised you didn't drop the motor.
Is there enough room for me to do base gasket with motor still in frame?

Originally Posted by Zergman

Sorry guys, long time no updates...

While I'm working I don't have the time to go get the camera, etc., so mostly I take pictures with my phone, if I take pictures at all
But I promise I'll make some HQ pics when tinkering with my bike later on (and I will be, because the carb needs some more adjusting). If you have any specific spots you want to see please feel free to ask, once I'm taking pictures I will show you what you want to see.

I ended up buying:

Raptor 660 billet aluminum fuel mixture screws

Raptor 660 air ducts

RU-4710 K&N air filter and filter oil + cleaner

Outwears pre-filter (air filter cover)
Honda CR throttle handle assembly

Honda CR throttle cable
Some "pit bike" throttle cable that had a 90 degree bend

Mikuni pilot jets #22.5 and 27.5 (#25 was already installed)
Mikuni main jets from #137.5 to #150 (#165 and #170 was installed)
Mikuni small main jet #80 for choke (#95 was installed)
Magura choke lever


Jet needles were already some after market performance ones, so I was happy I "saved" on them


Moving on to the "work" station:

the rubber cylinder head - carb boots were slightly modified, some excess rubber was cut out so that the carbs could go deeper in the boots. I had cut approximately 1-1.5mm, the "rim" that keeps the sealing collars (I guess that's what they are called) from moving too far to the carb side. Not in the pictures, but I'll make some pics later on...
The carb itself was ground down in the places that touched the intake boots, also to make it slide deeper in the boots.
Carb was re-jetted to Vando's specs (#25 pilots, #145 mains and needles on the second (I think) groove with thick plastic shims, which I later changed to #22.5 pilots and #142.5 mains, which are probably too lean... "to be continued").
Throttle handle, cable, 90 degree bend (from another cable I bought) were installed.

Choke lever and cable installed (cable was re-used, the one I took the 90deg bend off). The choke cable was shortened, and a cable tip that came with the Magura choke lever was soldered on.




Both carb diaphragm breather pipes were cut, shortened to approximately 1cm, to make more room for the breather hoses so they could clear the frame.
(picture with uncut pipes)


Then came the hard(er) part: how to join the Raptor 660 air filter-carb boots to the air filter? It had to be something simple, yet durable and small enough, so that the air filter is close enough to the carb that it clears the frame tubes. I got the joining part made from a 60mm metal pipe (yeah, I know, not too light, but heck, maybe in the future I'll get it made from aluminum).
It came out great, with two attachments to the original air filter box mounts (the third had to be cut off the frame). It also had a crankcase breather pipe, so my headaches of "where to connect it!?" were finished. And the air filter won't wobble up and down under the seat...








Okay, now I need to cover the air filter and mount the battery somewhere. But where? I thought I might need to make a special mount for the battery, then make the covers from tin metal (very thin sheet metal). But that's a lot of unnecessary work... And a heavy custom part too.
So I took my old air filter box, and started cutting it I butchered it to the point where I had probably less than 60% of it left.
So I saved the battery mount, flasher and fuse mounts, most of the mudguard surface. I also had it clearing the air filter and the metal pipe connector, so all good.

Originally Posted by turboguzzi

Zergamn = Belsm?