500 K cafe racer conversion - build thread

[Ewan 500 K1]

Carbs, K&N filters & front mudguard on.  Wiring loom installed, handlbar controls, headlight, rear light and indicators on.

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[Ewan 500 K1]

Seat and tank on

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[Ewan 500 K1]

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[Ewan 500 K1]

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[Ewan 500 K1]

Radiantz LED rear / brake light

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[Ewan 500 K1]

Just need to set tappet clearance, balance carbs, set timing, fill with oil and do the front brakes...... Might have a wee electical niggle.  Any suggestions on best oil to use ?

[Johnwebley]

ewan.looking good,

 see you have avon boots,

 it looks a work of art,

as for the oil,a semi-synthetic 10-40  should be perfect,

I am waiting with bated breath to see how it runs and handles !!

[Ewan 500 K1]

ewan.looking good,

 
I am waiting with bated breath to see how it runs and handles !!

me too John , its been a while in the making, just hoping my wee elctrical problem is a simple fix.

[Bryanj]

Forget the synthetic it's way over spec for the old SOHC. Tesco Mineral 10w40 Diesel oil is the correct spec, dont forget it needs changing every 1500 miles or at least once a year

[Bitsa (Ralph Wright - RIP)]

Agree with Bryan
They were made for the oil at the time mineral
Cheers
Bitsa

[Ewan 500 K1]

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[Ewan 500 K1]

So, set the tappet clearances & did the timing today and couldn't resist a wee hurl up the road, had the steering damper set at max.  Seem to handle okay up to a steady 80 and pulls cleanly right through the revs.  Back end is maybe a wee bit on the hard side.

Tick over is difficult to get right. After settling down after a flick on the throttle it sits too high on the revs, even after the thumbsrew is set right. To get it to slow down after the flick on the throttle I need to tickle the thumbsrew and still difficult to get it to sit at 1100RPM.
 
Worst thing is ... looks like I have a major oil leak at the head gasket, effin oil all over the shop. .. stud bolts were torqued correctly but I smeared the gasket with grease before I put it one , was that a mistake ?   On the other hand , if I remember correctly the gasket was in a job lot of 4 that I bought for a tenner a piece, so maybe its just a crap gasket ... or it might be the head gasket that comes in Dave Silvers after market engine gasket set.

Anyway, now got a head gasket to replace before I can get a move on.    > Ordered an OEM one from DSS  for mucho spondoolies, but he's out of stock right now.  F.F.S.

[Trigger]

Looking good Ewan, Did you get rid of our brake arm from the 750? I still have mine with the caliper

[Ewan 500 K1]

Looking good Ewan, Did you get rid of our brake arm from the 750? I still have mine with the caliper

sold for a whopping £6 Trig

[Ewan 500 K1]

having a closer look this morning , it might be the rubber packing between the head cover and the head thats leaking.. but there's so much bleedin oil its hard to tell for sure