Well wasn't going to be!

[Smallkat]

That is beyond my capabilities. Electrickery not my strong point. I will pop in a new 'old fashioned' filament bulb. Thanks Garry.

[Kryten]

That is beyond my capabilities. Electrickery not my strong point. I will pop in a new 'old fashioned' filament bulb. Thanks Garry.

Probably not the worst option

I didn’t realise that the 400/250 have a single Turn repeater. The SZ/SD have separate repeaters for left and right.

I still need to do that with the Main beam indicator, that LED is very bright.

[Smallkat]

The clutch needed adjustment, so the little screw-on cover over the clutch screw had to come off. It's one of those ridiculous half-round slots, but I did have an oil seal puller tool that fitted perfectly. That wouldn't shift it. I put some WD40 on and left it a day. Tried again, it's not budging. I took the cover off and applied heat. Not moving. I tried SAS freeze spray. Nothing.

It was going to take some force to move this, possibly damaging it beyond salvation. I checked if a replacement was available in the UK, which it was, so I then tried a drift and large hammer. Still nothing. Then I tried drilling two holes in it, which would take the prongs of my rotor holder tool.

I used enough force so that the prongs of my rotor tool were bending, but it still wasn't moving. The only way this was coming out was if I cut it out.

After lots of careful cutting, I managed to cut out half of it and remove the rest.

Corrosion had stuck the thing on better than any glue. I cleaned up the threads and face and put the new cover in with plenty of grease!

[Smallkat]

Replaced the fuel tap with the NOS item I bought from Garry (thanks!). You may recall the old tap was very close to the tank and even if you could find it with a gloved hand, you couldn't turn the bugger without pliers.

Of course, it couldn't be so simple as a straight swap. The old tap had its vacuum and fuel connections on opposite sides to the NOS (correct) tap. So I had to find correct sized hoses and clips to make it work. I decided to add a fuel filter while I was at it, although I'm not sure why, as the tap's own filter is very fine. I decided to use some thick-walled hose for the vacuum as I don't want it collapsing in use and starving the motor.

I am still waiting for a slot at my mechanic's place for the valve adjustment and carb balance. I am hoping that returns it to a good runner.
Unfortunately, it looks like this under the tank:

This is making me sad, so once it's running properly, I will ride it for the summer and then take it apart for a light restoration. I just can't help it.

[Bikeazoid]

Is your redline really 15 and a half? I really hope you don't test that.

[fossie]

Yep the redline on these 250's are 15.5 or higher in some cases,,,,,,. The valves are so small and clearances very tight.. They don't even make progress until 10.000rpm!

[Smallkat]

Yes, it's as flat as a pancake up to 10,000rpm. It doesn't exactly overwhelm you with power over that, but it is fun. I took it to 14,500 then changed up, as you don't want the revs to drop below 10,000 again! I wasn't brave enough for the redline, plus the valves need doing.

While I'm here, does anyone know if the front bodywork is the same on 250/400/1000/1100?

[geekay]

250 and 400 Kat fairings are the same, but completely different to the 750/1000/1100 fairings. The little Kats fairings are 2 halves, joined by various mouldings. The big Kats fairings are a 1-piece moulding.
I think I have some 250 / 400 Kat fairing panels in the loft - I'll have a look sometime.

[Smallkat]

Thanks Garry. There was a possibility of a reasonably priced big Kat fairing. Tinykat's fairing isn't in great shape, but the full resto is a way off yet.

[Smallkat]

Not had much time to do anything with Tinykat as I had three sets of forks to strip and get ready for chroming and powder coating. Also finally got my X7 frame ready for powder coat.

I have had time to change the speedo cable and starter cable. Both cables available in Europe. The existing speedo cable was too long and it didn't have the correct speedo head end, which made tightening it very difficult. The starter cable was just knackered.