A couple of weeks ago I completed the very simple task of removing the top end of the engine and after sourcing a clutch/flywheel holder and a flywheel puller I could carry on with the bottom end strip down.  By the way, the engine was working perfectly before I stripped the bike down, the reason [...]

My first attempt at aluminium polishing was pretty good but there were still small (but still visible) horizontal scratches in the finished item.  My first thoughts were that this was a “grain” in the sheet aluminium used to make the exhaust end can.  With this in mind, I decided to try the process again but [...]

I have a number of aluminium parts for this project that I want to polish but I have never actually done any polishing.  Last Sunday I made my first attempt at aluminium polishing on one of my exhaust end cans.  This blog post describes the method and equipment used.
This is how the exhaust can looked [...]

Just to clarify, Mildred’s previous owner had replaced the original TDR250 engine with a TZR250 (2MA I think) engine.  Even though it was running well before the start of this project I need to strip it down to have the cases vapour blasted. Once vapour blasted I am not sure whether I will paint the [...]

The last few parts attached to the frame should have been removed today.  The following parts were left attached to frame:

Rear brake light switch.
Rear suspension relay arm.
Frame identity tag.
Helmet lock.

The rear brake switch spring is looking a little slack and tired but the switch itself seems to be in very good condition and was easily [...]

Again, I had not been able to make a return visit to the project as soon as I would have liked but I braved the cold and cracked on the day after Boxing Day.  Here’s where I started the day:
The plan for the day was to remove the headstock and bottom yoke, remove the engine, [...]

I’d been away with work for just over a week so the strip down process was delayed  a little longer than I had planned.  The plan for last Sunday was to remove the cooling system, swingarm, rear brake system and the wiring loom.
Here’s where I started the day:
The first task was to remove the rear [...]

I didn’t get as much done as I had planned on Sunday as removing and draining the fuel/oil tank was more of a pain than I had expected.  I had planned to drain the fuel/2T oil, coolant, gearbox oil and rear brake fluid but did not quite achieve this.
I had heard tales about how tricky [...]

I’ve finally managed to get round to starting the strip down of my TDR250, a combination of traveling with work and watching Cheltenham Town has delayed things by a month or so.
I have big plans for this project but I’m not really sure how long it will take to complete but it will never get [...]

In my last TDR post (about fitting the underslung exhaust system) you may have seen that I thought the exhausts sounded like they were blowing from the manifold.
I spoke to the guy who actually designed and made the underslung exhaust system (martin77 at TDR250 Forum) and he recommended using some Permatex Ultra Grey gasket paste [...]