Honda-SOHC

Thanks guys that very helpful. I'll nip the nut up when my new torque wrench arrives my old Britool Torque wrench is a good 50 years old but the scale starts at over 30 lb ft so decided to treat myself to a lower range wrench that I will need for cylinder head bolts etc.

I had the Britool recalibrated a good 30 years ago when it was fitted with a new spring - I always undo the adjuster so there is no tension at rest. Sadly I tend to use impact torque sticks on our 4 wheeled vehicles - its just so easy!

The learning dip......................

Having assembled the clutch unit I've started to realise that I'm not taking enough photographs as I dismantle things as I should. I think to myself its obvious how this fits - then a couple of weeks later I find myself wondering how it all goes together again.

In my youth I could strip down a Mini Cooper S engine & gearbox - change a synchromesh using the manual only for torque settings and the like! Not sure if it's my age or that more modern motor cycles engines are so much more compact.

I have two workshop manuals that came with the bike - I am finding that they seem to be written for folks who know what they are doing.lol 

Thank goodness for this brilliant site.

Can't say it's 100% but one of the manuals I have has these torque settings:
(Attachment Link)
So 30 looks ok.

Thanks Deano one of my manuals does not seem to say or calls it something else the other had a figure like your chart but it seemed a tad on the low side - I guess I'm used to torque figures on cars that tend to be somewhat higher. Also its out of range on my old Britool torque wrench.

If its like most of the older generation vehicular ignition key arrangements you need ideally remove the ignition switch, insert the correct key initially. Find the detent plunger on the switch casing insert a thin rod or a straightened paper clip. This should then enable the key to come out of the lock with the barrel attached. Some very sneaky ignition locks have the detent plunger hidden by a thin film of alloy casting that needs drilling out first.

Once the barrel is out you will see that the brass levers are all flush enabling it to turn in the switch. Remove the correct key & insert the one you want to use instead. With the wrong key inserted the brass levers/plates will protrude so it will not turn the lock - you file these flat to adapt it. Depending on how different your keys are might result in almost any key fitting the switch. This can be avoided on some locks by swapping the levers around - it can be a bit of a nightmare though as the small brass springs can all pop out - depends on how the levers are retained.

THis has worked for me on old car ignition  switches - I'm thinking bikes are not that different.

That is as rough as a badgers a**e so probably a po mod

Flicker is down so at present better photo not available.

Yes Ted, that is correct. Have you fitted a new lock washer? as if you use the old one the tabs tend to snap off when you bend them over to hold the castellated nut.

Yes new lock washer the old one was a mess!

Thanks all. It turned out to be the rubber block hitting the rear frame bridge (the rear mudguard mounting point). I measured the new seat block against my genuine seat and it was 20mm thick, the genuine one is 7mm thick! I cut the appropiate amount off the new rubber block using a knife in-situ as I couldn't get the block off the seat, it would have destroyed the moulded bungs on the back of  the rubber block where they push into the seat base.  All now perfect . 
I have a buyer for the bike now, it will never be used as its going on display in his dining room! He's buying it as an investment as he doesn't even have a licence and has never ridden a bike before!

Sounds like the buyer has been watching too much Wayne Carini then again if he is young enough he will see a good return on his investment. It's interesting to watch where all this nostalgia thing for old stuff is heading - older generation buying things they wanted when they were younger and now having the dosh?