The Leviathan Project

[NINJA]

@Calum Yeah that would be interesting for-sure.

[Calum]

Just a note for myself in the future.

Front Master Cylinder 2002 RSV Mille
Front Forks WR250F 2003 Kayaba 46mm

That's the problem when you go custom, can't remember where half this stuff is from

[declan]

@Calum i do a similar thing if i need to remember some numbers or specs ill just send the message to my brother bit confusing though when he gets a random 47 come through in the middle of the night

[Calum]

Meanwhile on this project...

I have been enjoying the Athena kit so much I thought it would benefit from a mild port.

Off to Mick (who seemingly loves to chat about smokers on company time ) with the requirements.

In this instance I specifically didn't want the exhaust port raised, in essence the Athena kits power deliver is precisely where I want it. But the transfers, exhaust and powervalve did want a touch up.

Since the exhaust port wasn't raised I didn't need any work done to the head.

New piston, rings and gaskets ordered and I will endeavour to smash this on once that arrives, PJME said they are awaiting restock towards the end of this month.

All in all looks like a good job, but this is a VERY mild port for good reason. I have the RS for that screaming power delivery and I just didn't quite enjoy the peaky power of the ported 3MB once I had the RS and Cagiva.

[Calum]

@Calum finally managed to get this fitted yesterday.

Some chap on eBay was selling Titanium cylinder mounts.

As well got a nice Yamaha Tuning Fork engraved YPVS cap.

[markus.w]

@Calum I like that cap. Nice and subtle unlike the coloured plastic ones.

[Calum]

Well they had done superbly well...

I knew they need doing eventually. These were 10+ years old when I bought them and this has been my trusty steed for ~10+ years, once daily then stored for 4 years now just a weekend warrior.

Painless process to strip and rebuild and the kits are readily available on eBay.

All cleaned, rebuilt, new oil and refitted.

These are fully adjustable and I must admit, have just been on whatever setting they came with off the MX bike I bought them from. Since this is a road warrior, I've stiffened the suspension up a fair amount. I'll be interested in seeing how this now performs on the road!

The last ride out I did ~70 odd miles, the handling was becoming very poor. So I'm looking forward to the next adventure on it.

[Calum]

Getting there...

I am pretty happy with the design, I just need to modify where the holes go as there is that gap at the bottom I want to close up. It may just be easier to drill the holes myself.

I've got a quick print going now and I'll drill the holes myself and then remeasure it and do one final print. If that still comes out wrong then I'll just drill the hole myself.

Ideally it would all be part of the CAD so at least if, for whatever reason, I need another one, then it would be simple enough to sort out.

New rear disc ordered as mine is warped. Need a fresh set of tyres on this rude boy too. These are coming up for 10 years old now...wow 10 years scary to think.

[RikuRo]

@Calum Where did you get the kick start bc im making a street legal yz and i want to make it a kick start and yknits more reliable and passes easier thru registaration

[HOTSHOT III]

@Calum Is that a DT200R 3ET swingarm? Very nice, I bought one from Japan and it weighed literally half as much as the DT125R steel version.

However the plastic mud flap that protects the rear shock wears the (basically priceless) alloy swingarm away at the rear of the linkage bearing over time so it can be helpful to install something to prevent this. A lot of people with modern Huskies, KTMs etc. JB Weld a coin to the surface of the arm as they're prone to it as well.

I considered all that mud and chain lube floating about to be quite a harsh environment in which to try and glue two pieces of metal together so on my 250EXC I used the plastic sleeve which you get inside one of those boxes of sticky labels they sell in the Post Office cut open and cable tied on. Worked very well and I reasoned when it wears out you can easily make another one, but you might want to come up with a slightly more elegant solution for a road bike lol.