Bunkers MTatty 350 into MTourer 604

[Bunker]

Bought as a non running incomplete shed:

Overall I think it wont be too bad. There is a timing cover but the guide and bottom pulley is missing. I do have a spare non running lump to rob and there is a guide on ebay at the mo.

The airbox lid is missing, no seat (I have a spare) and no paperwork.

The silencer is mint and the headers/ Y piece are fine.

Tyres are mismatched and flat but wheels are excellent.

Fuel tank is mildly rusty inside and a few dents.

For some reason the hwole bike sits very low, the guy I got it from was quite short and it was his dad who owned it, maybe its been tinkered with to lower it?

Brakes work but untidy, no calliper top covers.

Ignition barrel removed but present

No side covers

No battery

No kicker

Switch clusters untidy.

Plan is to make it work, then strip and restore and register. Will then probably have to sell it if the wife has her way.

[Bunker]

I just stuck my kicker on it and it turns over nicely, no probs there

Left hand switch gear looks ok except broken/ missing indicator switch as normal.

Took off the scabbard, toolbox (empty sadly!), pannier frame (oh no, not another one....), rear indicators. Front indicators seized on, must have some WD40 somewhere....

No oil in the frame by the looks of it...mmm...I'm sure there'll be some, Ill check the patio tomorrow for evidence.

[Bunker]

you may want to add a skid/belly pan

its in the back of the van..

The pannier frame was an arse to remove, the longest bolts use a 17mm nut, a normal 17mm socket (must be a long socket) has walls too thick for the tube. Fortunately both had allen caps so I could 'trap' the nut and turn the bolt.

[Bunker]

ARSE! I just lifted the tank off to find the amp and coil MISSING!!!

[Bunker]

Found an old coil, no boot, ordered one from ebay (£4.75 inc P&P)
Picked up a new set of cables, air filter, calliper cover, timing belt guide, an almost new set of T63's, and an amplifier from a mate/ member (thanks buddy!)

Stripped off

rear brake assy
mudguards
rear light
cowling
indicators (one seized on so soaking in WD40)
rear rack
left rear footpeg brace (right one bolts through centre stand so left in place for the minute)
all footpegs and cross bar
brake lever
front brake assy (left dangling until forks come off)
disk guards
silencer - good nick but rattles with debris
horn
battery tray
airbox
switch cluster
chain guard

[Bunker]

I got my old donor engine back today (thanks Roy). Now to swap over the timing parts. I made a crank locking bolt (thanks for the guidance Apophis) which worked a treat exept I dont have a puller BUT ALSO found something weird. When I got the 24mm nut off, the thread on the donor engine is a bit 'squashed' and loads of fragments of soft metal broke out. Also a broken washer fell out - almost looks like someone has roughed up a washer then filled with liquid metal?....Anyone got a cam puller I can borrow please?

[Bunker]

Thanks all, I whizzed it over to Mr Kays who whipped it out with a rather nice puller (I must get one...). I reckon as the thread on the shaft is a bit flat, someone flowed the liquid metal in to bind it up. We'll see.

[Bunker]

Overdue update:
Today I collected the entire bike back from the powder coaters. Those guys are amazing, most of their work is MOD or NATO, the OD they used matched beautifully to Krylon (which is a quite dark, flat OD). The paint is MOD approved and is IR invisible - very useful!

I have stripped both wheels completely and had the hubs and rims powder coated too, will rebuild with stainless spokes. I now also have a pair of brand new shocks courtesy of ebay!

Frame number ends in 00001 which is nice (only means the first frame of that production run, not the entire lot!).

So the rebuild is about 80% brand new components that Ive been collecting for a while, the frame parts are mostly from MTatty but the engine is a 604 I picked up off ebay last year for £200 as it was 'seized'. Turns out the sprag had been incorrecly rebuilt which meant it locked in both directions thus the seize. Internals and bore etc are absolutely mint. Big thanks to zip tie and mart for their amazing engineering at Uttoxeter last year! Im using the timing/ clutch/ genny etc covers off MTattys engine to keep the original lines. Whole engine will be black.

I have a 22l plastic tank that Ill have covered in the fabric from an old Bergen, Ill keep the side pouch zips to each side of the tank so they can be re-applied as extra pockets. Found an upholsterer that used to make the seats for Formula 1 cars, he will be building me a touring seat once the rest is assembled (to ensure it fits round the tank etc)

I have a 3rd pannier for exhaust side, Ill probably put a gun scabbard on the other side.

I have an Apophis exhaust system on order.

Forks will be height increased with pre-loads and I may find a way to lower the pegs/ brake etc.

Will modify the cowl to accept an electronic tacho.

May fit a screen but certainly heated grips and maybe additional driving lights.

Pictures to follow....

[Apophis]

cant wait to come take a sneek peek

[MadStu]

I have a 22l plastic tank that Ill have covered in the fabric from an old Bergen, Ill keep the side pouch zips to each side of the tank so they can be re-applied as extra pockets.

Brilliant idea!