G'day All, After a lot of head scratching because of the cold start issue, success. Was about to launch into measuring fuel pump pressure and fuel rail pressure when I decided to do a load test on the battery. (Should have done that first). Load test was a big failure, down to about 8.5V. Whacked in a new battery which resulted in an instant start up. Next step is rego and a ride. Thanks again for all your input. Cheers Tom

great news tom ....woohoo

Good that it's all good. Will it be doing the Australia Day weekend ride?

Bill

That's good news tom. Good luck with the pink slip. Looking forward to seeing that beast on the road.

G'day Bill and Nige, No I don't think the yellow beast will be ready for the ride to Batemans Bay. It has yet to pass some reliability trials. There is also an issue with a leaking front brake master cylinder even though the O ring has been replaced. So , the trip will be on the trusty old 75. Looking forward to it. Cheers Tom

G'day All, Just a short progress report on the yellow beast. It is now registered but there is a major issue with the gearbox. Luckily a donor K100 is at hand... so removed the gearbox and clutch and found the rear engine seal leaking  badly. Have all new bits and pieces at hand and will transfer clutch and gearbox from donor bike into yellow beasty. I recall when Rossko replaced the seal in his 100 at RT's last May, the seal had to protrude by 0.5mm. My Haynes manual states the seal can be flush. Any thoughts on this ??. Would that 0.5mm make much difference?? Any input much appreciated. Cheers Tom

Apparently the new seals are slightly different to the original factory fitted seals from the era and so to run the seal lip in the correct position it needs to be 0.5mm protruding. I have never concerned myself with that and just make sure the seal surface on the clutch carrier is in good condition then put the seal in flush and all is OK. If you can feel a groove with your fingernail then it is not good. The surface often has a good coat of varnish and for that I use a scotchbrite pot scrubber and not wet/dry as it can leave traces of abrasive embedded in the metal.
Also I use new clutch bolts but hex head, you can get them from Repco and Supercheap on the Champion bolt range usually its a stand with blister packs of 5 bolts and nuts(7mm x 1mm) and you may need to cut them down but they are easy to get undone again not like those darn OEM stuff.

Thank You Rick, will take your advice on board. Tomorrow is fitting time and will keep you posted. If you hear of anyone having a short shockie, let me know.Cheers Tom