recently picked up a 69 CT1.  Had a backup engine on it, so am rebuilding original.  You never know what is inside. 
going to try and clean up the frame. some repainting may occur.  tool box needs paint and body.


* shift drum replaced; going to fab a steel chain guard for this if possible.
* 3rd gear pinion, several broken teeth
* wiseco piston 0.5mm over, with scar jamming rings though it had great compression; putting 0.75mm over in. 
* L crank bearing replaced
* R Crank bearing had seal against it

Easy way to install trans. remove this one pin and slide it in after installing trans axles.  Noted, both sides of crank had 0.6mm
shims and was ~0.024" clearance on both sides of crank to case. 


How do I know its in neutral.  look for the protruding ball on the shift drum.  This ball pushed another ball on neutral switch to create a ground
for the neutral light


Can also check neutral from here.  


this is disassembly.  see seal.  installed a little too deep for my comfort though I was not sure if it was leaking or not. 
I had planned to replace them all anyway, so no testing. 


Not sure if I should do anything w/this or not.


Ready for Yamabond4 and assembly, hopefully Tue.






Is getting repainted original colors on fenders and I'm going to try PeteRT1's badge idea on repainting red to black for badges.  (q tip + acetone and carefully remove red) ; if cost get too high, I might have to print one on the HP laser and use it for a while.

 

Nice shots of the assembly, looking clean.

I gave the cases a bath in the Ultrasonic. It was a mess when I started! I'm just trying to get the original engine to reasonable running order.

While I'm assembling the original engine, I'm looking at what is needed to redo the 2nd one. I have a cylinder being bored and a piston for it, but ran in several case issues. The L cover (chain injury), L main case (shifter below pic), R main case (near oil pump, stud mounting point cracked and missing), R case cover (impact injury), are all damaged.
Hate to abort the build as I have all the other parts.

"(q tip + acetone and carefully remove red)"

Paul I didn't use any solvents, just the rounded edge of a penknife was enough to scratch off the red paint from the underside.
I'd be worried that using the acetone it might be easy to accidently get some bleeding into the recessed silver lettering.
When painting I used a black primer for adhesion, followed by a gloss coat as the primer would be susceptible to moisture.
Let us know how you get on and what method you used, good luck.

thanks Pete. I'll post up when I get that far. Thats paint and body...a ways out.

Engine coming together. At least spins freely and appears to shift ok.


Cases were a mess and had silver paint on them.  Brushed them out w/AlumOx. 





 

"Cases were a mess and had silver paint on them.  Brushed them out w/AlumOx."

Paul, '69 and '70 CT1 had painted engine covers.
Had a good look at your bike and it looks very original.
Obviously the red stripes on the fenders are not, but at least the front is still the correct aluminiun version.
It's a great find for sure, looking forward to see it back up together.

I knew you would bust me for that! Yeah, just trying clean the poor bike up. If it looks too bright after done, might spray it over.

and of course the mag side...

Note the polish I use ( chemicalguys.com Heavy Metal Polish ) helps reduce future oxidation. Coats the metal in a way to protect it.

In the case of this bike, I am simply cleaning it up...this is not a resto. Next up, going to clean the frame, then pull fenders, headlight bucket, and tank for body and paint. The forks don't appear to be leaking, so maybe leave well enough alone there and just drain, replace oil.  Torque spokes, change out sprockets, chain. 

I think I have an unknown year AT1 or AT2 bottom end sitting around if you want it, I picked it up for $50 years ago to rob some clutch parts off of for another bike. I'll be around where it's stored away next week and let you know, if it's around you can have it for the cost of shipping. MarkT will know if there is enough crossover for this to be a viable option

Edit, might be a '74 DT125. Anyhow I'll check the vin when I'm there.

"I knew you would bust me for that!"
Paul, sounds like you've got the right idea with your approach I certainly wasn't criticising .
I get a bit obsessed at times with originality (to a point) when I take a project on.
I'm happy to concede powder coating over paint on the frame and other black parts, partly because it's cheaper, less time consuming and it's damp here in the UK.
I don't have a problem with reproduction brake switches or levers, but on the whole I like originality where it's fits within a reasonable budget.
I waited nearly a year for a correct Stanley RR30 reflector to appear on eBay, despite have a pair from the '71 model sat in my garage.
Problem I have now is I've created such a lovely looking bike in the '69 CT1 I don't want to ride it and get it messy.
I think it's likely I'll try and thin my collection this year, moving on the '69 CT1, the CT1-B "The Doppelganger" and possibly the AT1-C, that will leave me with The Greenie and The C.
Whilst I enjoy restoring a bike I like the freedom to ride a bike that I'm not so precious over.
Just my thoughts.
It does look good though, maybe I'll keep it