sorry bout that

Well, bit more progress today.

Bolted up the exhaust, but it really does sit quite low.



How have others moved theirs up? I think I'm going to have to get into Maidstone to a good exhaust place and get a mild steel link pipe made!
Anyway, all the electrics are in including the 600 clocks as I couldn't be bothered to splice in the CDI.



Then came the cooling system. Mounting the radiator with a couple of bits of bent ally went fairly smoothly, connected up all the pipes and remembered someone mentioned that they turned the top hose around to get better bends. It works!



After the cooling system didn't leak (much) I decided to give it a go and see if she would fire up...
Everything looked good, tank on, carbs connected, battery in and connected.



WE HAVE LIFE!!!!

And for a road legal Micron system, it's flippin' loud!

Now comes the tricky bit of tidying it all up, fitting all the plastics and making sure the wiring loom doesn't get caught in anything.

Alex.

I heated the pipe up with a gas axe and slowly formed the pipe to the shape i wanted it. It wasn,t quite as low as yours though before i bent it, it was just fouling the shocker links. Looks like it might be a bit close to the plastics

Spent some more time in the garage today and made more progress.

The tacho was doing it's diagnostic dance to 8k, turns out it is something fuel related, either pump or tank sender. Found that if I put on a different 400 tank the problem goes away. This came out of the problem tank...



Most of the time today was spent trying to get the exhaust to fit. I ordered some 2.5" bends from Jetex, just to see what I could do. Could be better, but it will do for the MOT!





A couple of days ago, I put on all the plastics just to what it looks like. Not too bad! Looks quite standard too...



Just minor tidying left and getting the log book back from DVLA with the correct engine number!

Alex.

I do have a couple of problems though.

I have used the throttle cables from the 600 as the inners of the 400 are not long enough. They fit alright, but due to the routing that they need to follow their action is not very smooth and the return is slow.

What throttle cables have others used on their hybrids?

Then the gear linkage! No matter how the splined bit is put onto the gear change shaft, it doesn't fit. Either the linkage rod hits the frame or the gear lever hits the rod. The splined bit (I really should have taken pics of this part!) is different between the 400 and 600, I may have to have a play with both these parts and their rose joins.

Any hints from other hybrid builders?

The missus is off at her mothers for another few days, so I'll be able to get in the garage and sort these issues out!

Alex.

looks great alex,the black and gold looks really classy.i just used a single 400 cable and it works ok and returns ok but i cant remember modding it in any way (though i do have the memory and recall of a pair of slippers)im going to take the airbox apart in the week and if i remember i will take some pics for you of the throttle linkeages.post a pic of the gear linkeage,i think i used the 400 sprocket cover as the 600 one has a much deeper hole where the clutch cable fits and it makes the clutch action horrible,anyway classy looking street sleeper mate-steve

Thanks Steve, pics of the throttle cables would be great.

Funny you should mention about the clutch cable, I found the same thing! All I did was use the 600 clutch cable, but it is a bit long and may foul something later on. Does the 1WG casing fit the 3TJ and by extension the 600 foxeye?

Alex.

Steve, I fixed the throttle cable!

I used a single 400 cable like you, but I had to shorten the outer by about an inch as there was absolutely no free play and the carbs would have been permanently at full throttle!!!
After the chopping it all fits just right, no more big loops and quite smooth action.

Thanks Steve!

Alex.

I used the 400 throttle cables but had to modify the mount on the carbs as i think the return was slightly different. As for the clutch i used the 600 housing and didnt have any problems with it being clunky but i have had problems with the clutch slipping but thats not related in any way, just a badly adjusted push rod to blame.
Looking good though! Im getting tempted to rob the bodywork off the new fzr ive just bought and get mine MOTd. Roll on the rollout!
(told you to check the sender!)

Blimey, it's been over a month since I updated this thread!!

Today is a landmark day, she now has an MOT!!

The bend in the exhaust has been replaced by a flexible pipe, so it no longer sticks out too far.
The bent clip on has been replaced and some Maxton forks fitted from an ex-race bike.
Lots of tidying up and a ride to the MOT test centre.

I'll take some more pics later and I've just got to wait for the DVLA to finally send me a V5 with the correct engine capacity so I can tax it. They did want additional proof of the engine capacity, but a nice lady at Yamaha UK sent me a letter with the appropriate info on and that is all in the post to Swansea.

Still got some jobs to do, but I should be ready for the summer....

Alex.