First Generation Ascots > The Thumper Years: Modified To Full Customs

Dutch FT project

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hellblom:
I got the tank on, next up is changing the seat and putting a hoop in the back. Going bratstyle.

FT500R:
@Hellblom.
Looking good, really needs a smaller seat now ;)

I've bitten the bullit and I will do the kickstart conversion.
Ripped the engine out this morning and did a check if indeed there is a hole for the kickstart (better safe then sorry).

The engine is now upside down on a little workbench because I will be splitting the block by taking the bottom half of instead of the full head, cilinder, and then splitting from the top as per the manual.
I will keep making foto's of the process so let me know if there is a need/want for a write-up of how to split the engine upside down too ;)

Officially ordered my XL parts now, so what I have coming my way:
- Kickstart axle with all springs etc
- XL clutch cover, you can take the plug in the kickstart hole out of your FT cover but you would still miss the hole for the automatic decompression, as I want to have this system I just got the correct side cover and lever.
- XL cilinder head cover with decompression handle and spring. You could have your FT head cover machined or... just buy the piece
- XL decompression cable
- XL stator cover. I am going to see if I can fit the FT stator in this to really clean up the engine and loose the whole e-start part.

J6G1Z:
I've owned a Honda XR400 (Bored to 440) & an XR600. They are not that hard to kick start once you learn how. Cycle the kicker slowly to bring the piston up on the compression stroke. I used the separate compression release lever to bump the piston just past TDC on the compression stroke. Allow the kicker to return to the top & then boot it. That is the only time I ever used the compression release.

FT500R:
I managed to split the engine today!
Write up on how to split it without removing the top-end is in the tech section.
It was not that hard at all.
One downside was that one of the axial set rings for the main bearing of the crankshaft broke... one small part ended up falling down the camchain tunnel towards the head. Ill get that bastard later.

I also added a picture from before splitting the engine, if you look through the hole where the sump normally is you can perfectly see the hole where the kickstart axle will come trough, you can also see the hole where the return spring retainer will protrude. I think it might actually be possible to fit a kickstart axle to a FT without splitting the cases.
You would have to take the clutch of though as you need the room to access the bolt hole for the return spring retainer.
To me knowing how easy this was, it almost seems like taking the clutch of is more effort than just splitting the cases :D

hellblom:
Many many thanks that you are sharing your efforts with us. I will probably do this work in a couple of years and your pictures and thoughts will help.

For me it is time to change the seat this week, working from home has it's advantages.

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