Since the last post, which outlined the throttle linkage design, I’ve done some of the fabrication. Because the pieces are fully three-dimensional and not prismatic, it takes a bit of care to make sure that they can actually be fabricated. If you design some thing that has no parallel edges, it’s very difficult to hold …
Continue reading ‘Microsquirting the NC30, part #38: Fabricating the throttle linkage’ »
As mentioned in the last post, it’s time to start working on the throttle linkage for the NC30. The requirements for this setup is that it needs to be possible to adjust the throttles of cylinders 1,3, and 4 against the cylinder 2 throttle, which is attached to the throttle cable. Since the GPz throttle …
Continue reading ‘Microsquirting the NC30, part #37: Throttle linkage geometry’ »
After fixing the fuel supply line, I finally got the fittings needed to hook up the fuel pump outlet line, too. With a 150-degree fitting after the fuel pump, it routed perfectly between the fuel pump housing and the battery. Routing the return line was a little bit trickier. As shown in part 19 of …
Continue reading ‘Microsquirting the NC30, part #36: Idle tuning’ »
One of the few remaining tasks was to hook up the fuel line from the fuel tank to the fuel pump housing. This is just a short length AN-6 hose, nothing complicated, but I was not entirely certain that it would actually be possible to get access to tighten the AN fittings. After receiving the …
Continue reading ‘Microsquirting the NC30, part #35: Fuel supply line’ »
In the last post, I outlined the change to swap out the leaky clamp joints on the exhaust header pipes for double slip joints and got as far as cutting the old clamps off the exhaust. I’ve watched a couple of videos on fabricating exhaust systems and they all make the point that the fit …
Continue reading ‘Microsquirting the NC30, part #34: Finishing up the exhaust’ »
Ever since I bought the NC30, I’ve been unable to get the joints where the front cylinder header pipes attach to the collectors under the bike to not leak. The joints are clamp joints with a cylindrical fiber gasket, but I could never get the gaskets to fit inside the clamps. After asking on the …
Continue reading ‘Microsquirting the NC30, part #33: Fixing the exhaust leak’ »
As I started working on hooking up the fuel pump, I also realized it was time to make new battery wires. Because the Ballistic lithium battery is much smaller than the original lead acid one, the existing positive wire was too short, and the ground wire is fraying, so I decided to redo that one, …
Continue reading ‘Microsquirting the NC30, part #32: New battery wiring’ »
Way back in June, I talked about making the parts for the fuel pump housing. Since then, I’ve slowly been gathering courage to weld it together. My first practice runs welding together 1.6mm (1/16″) 6061 sheets were not encouraging. It’s just very easy to blow out one of the sides if you add a bit …
Continue reading ‘Microsquirting the NC30, part #31: Finishing up the fuel pump housing’ »
After getting the idle air control stepper motor working as desired in the last post, it was time to clean up the installation a bit. First, the stepper motor had to be wired up. This necessarily involved yet another hole in the airbox to get the wires out. I drilled a hole next to the …
Continue reading ‘Microsquirting the NC30, part #30: Finishing up the airbox work’ »
The last post ended without holes to mount the idle air control valve. This turned out to not be a big deal. There’s a raised edge around the entire airbox casting that I could rest it on while clamping it to the mill table. With the holes drilled and tapped, the valve fit perfectly. The …
Continue reading ‘Microsquirting the NC30, part #29: Even More Idle Air Controller’ »