dave62

Thanks folks, I'm really enjoying doing this rebuild. Soz blackhat, I couldnt make the rallys this year (long story involving redundancy ect) but all sorted now so hopfully back on track for next years

Hi all, appoligies for the long delay in updating but sadly work keeps getting in the way! After getting the age related reg sorted I decided to crack on and sort out the front end. First job was to strip the forks and get the Stanchions re chromed. When the Stanchions came back I began the rebuilding. With the front end complete I turned my attention to the paint Thats as far as Ive got but now waiting for some cables and need to sort out the tank badges. Time for a glass of red I think!

Yes, me to. I thought that any bike imported before 15 April 2013 did not need to be on the NOVA register and could be processed with the old C&E 386 (this may still be the case) but confusingly I had read somewhere else that the DVLA would no longer accept C&E 386 as proof so I decided to ring the HMRC Clearence Hub who were very helpfull and told me to send the 386 to them and they then sent me confirmation that all duties were paid and gave the bike a NOVA reference which seemed to please the local DVLA office.... I'm not sure but I think you can get a NOVA reference online, but might be for trade only

Finally managed to get the A.T. registered with an age related plate so thought Id share my experience for anyone about to do the same. I've never been through this process before and mix in the 'NOVA' changes,I wasnt looking forward to it one bit First thing was to send off for the free info pack from the DVLA it gives some good help and advice on how to fill in the relavent V55 form (also included in the pack) Next off was to get a dating letter to verify the age and model details. (easy bit) Then, due to the 'NOVA' changes, I had to send my original C&E 386 to HMRC who then sent me a letter confirming that all the import tax had been paid and giving the bike a NOVA reference that the DVLA needed to proceed So now all I had to do was provide an MOT and an Insurance Certificate (both done on the frame number) and some I.D. oh and the £55 Regisration fee. (age of bike makes it tax exempt tho) So armed with all this I went to my local DVLA and amazingly was back out 20 miniutes later, job done Just need to wait for the paper work to come through and I can get a plate made up. Happy days.....Dave.

And the front ..... Also started to build up the frame and refit the engine. Hopfully be back soon with another update....Dave.

Managed to get a few more jobs done on the old A.T. Seeing as I'd now got all the zinc back, I decided to rebuild the wheels. Started with the rear as its got 3 different spoke types and some off set to deal with. I took loads of pics and made notes before striping the wheels. Just kept going and after a couple of tries ended up with a finished wheel which I then trued up with a dial gauge and the wheel in the swing arm.

Well, its been a while since I last updated but have managed to move things on a little. The Engine is now back together with all new bearings and seals (except for the barrel and head which still need to be cleaned and re painted along with the outer cases) Also managed to get hold of a nos 2nd oversize piston and rings that I will keep on a shelf as spares. The fork stanchions have come back from Philpotts after being re-chromed and look as good as new but the fork lowers and other painted parts (mudguards, tanks ect) are still with the painter so cannot start rebuilding them yet. The Frame and other black parts are at the powder coaters but I hope to be collecting them next week sometime, so in the mean time I sent all the Zinc plated parts off to be recoated along with the rear shock springs for re-chroming, these came back real quick so I started to clean/polish the wheel hubs ready to rebuild the wheels and also refurbed the shocks. Cheers....Dave.

Watching with great interest well impressed that the lecy start worked. Please keep the pics coming

Got a few more bits sorted, first job was to finish making some replacment carbon brushes by cutting down some larger ones. Ive used two different grades of carbon to see which will perform the best...time will tell Had some luck on fleabay and bagged a Nos points cam (in the UK too) to replace my knackered one Have now finished cleaning and inspecting the cases and gearbox internals and all looks good. Result. So should be able to start rebuilding very soon. Have got all replacment bearings chilling nicely in the freezer (mrs not too pleased though) Cheers...Dave.

Thanks for the tip, will look out for for a second (.5) o/size piston and keep on the shelf till needed. Good advice, thanks

Few more Fizz pics...

Got a few bits done. Crank case Kickstart area has now been welded and just needs a tidy up with the Dremel. Had the Crank rebuilt with new bearings ect and had a chat with the guy regarding options for the rebore. Cant find a first o/s piston so followed his advice managed to sorce a standard piston which I will fit for the mean time until an o/s one turns up. Hes run a reamer through the bore to clean it up as much as poss so will be better than before. Got fed up searching for Generator Brushes so decided to try and make some. Time will tell if any good.

UK_DT, will try and put up some more pics soon mate, Cynic, I rode this fizz every day in all weathers for 3 years (took me that long to pay off the HP lol) back in the day and learnt how to decoke and set points ect too John (blackhat250) cheers mate but will be going to RD rally as its only 5 mins from home for me so if you are around I'll let you buy me a pint!

I am investigating getting it welded first as a proper repair but will bear in mind your "low budget" idea if welding prooves to be a problem. Thanks

Found a picture of a good crank case half on the internet. now at least i know whats missing from mine A couple of pics for comparison... first the good case, (kick start area) and second my bad case,

Thanks busyeddie, will give tyre finder a call Been busy stripping the engine down so heres a few pics (and some questions) of progress so far. Engine out. Scoring to bore and piston. Rebore? cases split I think this may be the cause of the kickstart problem? (intermitent not engaging/disengaging) It appears that a lug is missing and allowing the kickstart tang to rotate. so my question is... Is this a common problem and is there a recognized repair? Im thinking maybe get a lug built up in weld and dress back? All opinions welcomed Thanks in advance....Dave.

Cheers John, Mot passed today so will start stripping it down now and sending a few bits off while I wait for my dating letter to arrive, then off to Dvla to register hopfully before any changes come in to force.

Yep dwheel on the Triples site mate How ya doin? Problem seems to be the 18" front as most seem to only cater for 21" Thanks for the High Level tip will check them out...Dave.

Hey up John lad, Yes the block trials types what I want, have tried Vintage tyres but they couldent help and will be having a look at Tyerfinder as sugested by busyeddie, any ideas where else to try?.....Dave.

Thanks for the comments Heres a pic of the original (bent) bars. Decided they were too bad and have now swapped for a better set that will do for the mot. mot booked for tommorow so fingers crossed.

So here is my AT1, bought as a non running import from a local restoration business. Story goes that it was only used to drive a mile up a track to the mail box and back again each day so never got registerd in the US for road use hence no title but it did have the C & E 386 to say all UK import duties paid. Plan is to get it registered on an age related number but as I've never done this before I'm learning as I go. As far as I know I will need: 1, dating letter (yamaha owners or vjmc) 2, mot (on frame number) 3, insurance (on frame number) 4, dvla form v55 5, fee 6, tax disc While waiting for the dating letter to come back I've got to get it ready for an mot. First job was to get the engine started, cleaned out the tank with some old nuts and thinners plus lots of shaking and stripped the carb down nothing too major in there apart from the float bowl is perforated in several places, bodged this for now with some JB weld but will need to sorce a replacment at sometime, Anyone? Fitted a new set of points and pressed the starter....nothing! turns out the generator brushes are worn out so made up some replacements and....still nothing! good job its got a kick start so I give it a couple of prods and find that its to got issues as well, it does not always engage so reverted to bump starting and it finally splutterd into life and then it ate its crank seals! Got two replacments and they were thankfully easy to change. Starts dead easy now even with the faulty kick start. Next on the list was new tyres. Had problems finding knobleys in the correct sizes (18 X 3.50 & 18 X 3.00) so opted for a pair of cheng shin road tyres for now. Sorted out a couple of blown bulbs ect and replaced the brake shoes front and rear. So apart from a few minor adjustments I think its ready for the mot. Heres a few pics and a vid (hope it works) Cheers...Dave. ...... ps. Anyone know if bent handlebars are an mot fail?

Big thanks TTB, very usefull info and links.

Thanks guys, Im very pleased with it, its only showing 4500mls and has been in a very kind climate somewhere in the U.S. as theres no significant rust or damaged chrome. Would have looked a bit different if it had had 43 English winters I think! I'm in the process of getting the age cert from the vjmcc and have spoken to my mot guy but I have to get it running before he will test it. (lights and horn work independant of engine running so i thought i might get away with a dead engine, but no) The electric start only turns the engine over very slowly when the plugs out (wont over come compression with plug in) and the kick start has issues as well, suspect the return spring lug may have broken off in the crank case? so plenty to sort out before mot. I've read some bits about the DVLA changes but not sure how i will be affected, I have the C&E 386 doc and will sort out the rest but would welcome any info regarding the DVLA changes. As I start getting more into it I'll try and document it in the "Projects" section. Oh and if any ones got any tank badges they want to part with.......Thanks in advance....Dave .

Heres my next long term project Considering its 43 years old its in very good condition, its a non runner so will need plenty of tlc to get going but for now im sorting out the paper work ect in order to get it registered (age related)