- Politically Incorrect
.. restoring an 1987 ATK
3 4 or so years ago, on the way to SX races in San Francisco, my buds unmercifully harassed me about failing to complete the ATK project.
"Tell me again how you have a complete rolling chassis and it STILL ain't running?" asked Jack. "Hell it's only been apart for 7 or so years" I retorted. Besides, I'm a busy MoFo".
That's when Jack chimed in; "I'll stuff that engine back in the frame, wire it up with Baja Designs components, fix all the broken crap for you. Toss me a 1,000 bill and I'll make it happen, parts cost only, free labor."
"I'll ask you again tomorrow, Jack, when you aint been drinking" sez I.
Roll onto tomorrow, and Jack is sticking by his story.
So, after spending some time under Jack's tutelage, the ATK is ready to make the journey back home. it should be back sometime August 2010.
The only problem is a nagging ignition issue. After running for a bit, it loses spark. I just happen to have some spare parts laying around the house (I raced MX on this bike 87-91) so I can throw them on shot gun style and see what happens. IIRC I have ign coil, rotor, stator, cdi. But that motor always had weak ignition - although it would always run.
Researching the net, it *appears* that CDI modules are no longer available for 87 and earlier XR's. I hate to think about buying an 88 or newer just for parts, but I can and will if needed..
The bike, at my buddies house.
Over last weekend, got the mighty ATK running.. new secondary coil, from the parts bin. Then, worked on detail stuff..
making hose clamps the right size, found some OEM Honda brake pads for the front (nothing there when bike sent/received).
The next step is to buy control cables..
Apparent sources are flanders.com, motionpro.com.
The local guy wanted 50 bucks per cable.. so I balked.
It turns out MotionPro can make cables.. so I took some pix of the dimensions -
|Inner cable OD
|Throttle end ferrule. Both ends look the same.
|Throttle ferrule big diameter.
|Carb end OD.
||Carb end boot.
|Cable free play. Note that it would be tad longer because the adjuster is taking up some slack. See pix above for adjuster.
||Overall outer sheath length.
hmmm, this looks good <clicky>
Here's some updated pix..
Problem - CR250 brake/master cylinder assembly on Easton Flex bars (remember them?) in conjunction with Magura 314 throttle assembly has all sorts of issues. In this pix, the throttle tube is cut down by approx 1" - see the compressed grip - and it just ain't enough territory to hang on to. I need to find a throttle assembly with a smaller OD to clear the Honda brake lever adjusting nut.
More pix of the project bike..
The ATK anti-torque system. Pulling in a straight line eliminates suspension compression under acceleration. Take your bike, nose the front tire against a wall, apply throttle and a little clutch. The bike will squat. The ATK remains level, allowing maximum speed in the whoopage.
Spent most of Sunday working on the ATK.
2011-01-26 First Ride Today
..but first, some previous work to catch up on -
2011-01-30 A rainy day
Last day of the first month of 2011, got to say I've been wrenching more this month than in a long, long time. Kinda fun except my hands hurt. And back. And feet. But what the fuck, this is really kind of fun. So I ordered up this really cool Moose racing clutch lever/hot start (for me, decomp lever) and bummer what a fooked up idea this turned out to be. I completely missed the boat when at Hidden Power Cycle Clinic - forgot all about the the switch assembly. Sigh.
Oh, well, live and learn. Moose also carries dual purpose levers that carry the hot start (decomp) on the top side. I measured the cable holes, where the cable end fits into the lever, and the current decomp lever had the same size, but was not deep enough. Not sure if this will ever work, and I have some time this afternoon, so why not play a bit and see what works with hardware on hand?
Taking a break from the lever project, I saw that K&N makes a filter that has slight downward angle to it. As seen in other pix, my current filter angle isn't really right for the airbox and will hit seat bottom. What's more, it does not really fit well onto the carb bell. Not good enough at least.. I needed the bell diameter to order the new filter.
Just saw this tonight, and I'm somewhat concerned. This is the aluminum intake manifold mating the Mikuni TM38 carb to the XR600 engine. I have questions about the epoxy - is it strong enough? Will it withstand heat cycles and vibration? Why is it there? Seems a good weld would not need additonal sealer?
Also, did the following
Well, it is Sunday night and I need to get outta here..
maybe tomorrow I'll change this site up where new posts go to the top and not the bottom. It's a PITA to scroll down all the time for new info..
2011-03-09 Progress Report
Lower chain guide fabricated from pieces of an old water tank. No idea how tough the plastic is, but I got a ton of it.. to test, make various templates, then when finalized make out of Delrin or something?
Baja Designs sells Acerbis components. Check out this rubber rot after less than 1, 2 years max? And this has been with inside storage, too.
..and check out the rubber behind the relay flasher..
The brake light bulb was staying on all the time.. See comments below, I wasted lots of time to find nothing more than defective bulb that would illuminate both elements even though only one contact has juice..
..and check out this 'virgin' tail lense - looks like it's melted..