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British Bikes / Re: Troubleshooting a JAP Special
« Last post by Rex on August 06, 2026, 06:19:24 PM »
As an aside, I always use Jubilee/worm drive clips when the bike is still in the "fannying around with" stage as then are easily removed if required.
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British Bikes / Re: Troubleshooting a JAP Special
« Last post by Rockburner on August 06, 2026, 09:43:31 AM »
The Norma ones are just to show the type I use. They make them for use on car EFI systems so they can be got in smaller sizes.

Gotcha, something to look at as a finishing touch, got bigger problems right now.
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British Bikes / Re: Troubleshooting a JAP Special
« Last post by murdo on August 06, 2026, 08:36:53 AM »
The Norma ones are just to show the type I use. They make them for use on car EFI systems so they can be got in smaller sizes.
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British Bikes / Re: Troubleshooting a JAP Special
« Last post by Rockburner on August 06, 2026, 08:29:32 AM »
I have been following your rebuild with interest, and would like to make one comment. The hose clamps you are using are squashing the crap out of the rubber hoses and I think maybe letting some drips of oil leak out. I always use the full band type on soft rubber hoses. Yes, they may be a few coins dearer to buy but they dont smash the hose and are easy to reuse.
https://valvewarehouseaustralia.com.au/products/norma-gbs-stainless-steel-hose-clamp-heavy-duty-t-bolt-w2
Enjoy the rest of the ride.

Interesting.   

The Jubilee clips seem to be doing a good  job at the moment in terms of sealing, and I take the point that they appear to be squashing the hose significantly.  I think the fitted hoses are particularly soft (the wall thickness is huge on them) though, which may be giving a slightly false impression of over-crushing.

I would point out that the Norma clips only go down to 17mm-19mm... that's too large for most of the hoses on this bike, they're not more than about 12-13mm outer diameter. 

I use Norma style clips on the Exhaust clamp though, and they work very well.  (I also have a couple of more modern BMW bikes, which use Norma clips on the exhausts).  I believe they have a limited range of hose capacity (which is why there's so many sizes on offer).
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British Bikes / Re: Troubleshooting a JAP Special
« Last post by murdo on August 05, 2026, 11:09:03 PM »
I have been following your rebuild with interest, and would like to make one comment. The hose clamps you are using are squashing the crap out of the rubber hoses and I think maybe letting some drips of oil leak out. I always use the full band type on soft rubber hoses. Yes, they may be a few coins dearer to buy but they dont smash the hose and are easy to reuse.
https://valvewarehouseaustralia.com.au/products/norma-gbs-stainless-steel-hose-clamp-heavy-duty-t-bolt-w2
Enjoy the rest of the ride.
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British Bikes / Re: Troubleshooting a JAP Special
« Last post by Rockburner on August 05, 2026, 08:46:27 PM »
I played hookie from work this afternoon and made a small change I've been thinking about for a while:

I rerouted the oil feed line so it doesn't "hang" and drip oil onto the frame when it gets any oil on it


It was running through a gap between the gearbox and the engine plates, now it runs under the mag platform.

As a benefit I've lost a huge amount of weight from the bike
A whole three and a half inches of rubber tube! :lol:


Had a slow ride out to a bike night nearby


The bike ran mostly ok... But there was something off...

And then when I went to leave the cafe, it wouldn't kickover.  The kickstart worked ok, but it wasn't turning the engine over, and I realised that the clutch was slipping.  Eventually I got it fired up, but it's definitely slipping, the ride home made that obvious.

I also tried another compression test when I got home, 90psi. Hmmmmm. (Yes I held the throttle WFO).  I need to find out if I fitted new rings or not, I can't remember.

In the good news the engine is nigh on oil tight... (Ok, it was only a 15 mile ride, but that's a perfectly acceptable level of leakage for a 70 year old... ;) :D )


I daresay tomorrow will involve spanners.....
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British Bikes / Re: Troubleshooting a JAP Special
« Last post by Rockburner on August 04, 2026, 08:21:45 PM »
I was going to go visit the Selsey JAP man, but the weather was inclement so I demurred...

Instead I started out by doing some minor work around the tank area, and ended up drilling a new hole in the head steady to mount the coil further up away from the engine head, and in between the tank halves, it's nicely out of sight, but should still get a flow of air over it.

I also checked the gap on the spare plug in the toolkit and adjusted it to be what is recommended, just so I know that if I need it when I'm out on a ride, it's all setup.

I then caught sight of the exhaust, which is covered in oil drippings (not as nice as beef dripping... :D ), and thought, ok, I'll have a quick go and see if a that will do anything...


3 hours later... I was still in that zen-like state where you think "ok, I'll just do that bit... then that bit..."


It may not be perfect... but it's a vast improvement!


The dead on the battlefield...



Ahem. :D




Good enough for now, it'll be a lot easier to see what the drippings are now for future rides.

Hoping Thursday is good weather! :)
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British Bikes / Re: Troubleshooting a JAP Special
« Last post by Rockburner on August 03, 2026, 07:16:09 PM »
Apparently all the oil I lost on Sunday was generated from the dark matter of the universe...


7cm is exactly what I measured Sunday morning before I went out.

I wiped up some of the dribbles, then started looking at the plug because re reading the link about the Magneto, I realised I'd never checked the plug gap.

Apparently it should be between 0.018" and 0.020".

"That went in a bit too easily" (Bishop, to Actress, 3rd September 1933).


So did that...


So I dug out my Champion Plugometer! :D


What, you don't have a Champion Plugometer?






Call yourself a petrol head? Tchah! :roll:

:)

Anyway.... The gap was definitely a bit wide so I tweaked it down and hopefully that might make a bit of an improvement.

I WAS going to try to straighten up the little nose cone, but after I took it off, I'm realised the thing is actually twisted au natural.... FFS. So I put it back on.


Another little job I wanted to do was to round off the fly screen. So I had a go at that with the Dremel and a small file.

It's not perfect, but I'm reasonably happy with it for now.




I may have an hour or two of time tomorrow to get out on it again, still want to see if the Selsey JAP man has any info on one or two questions I have.
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British Bikes / Re: Troubleshooting a JAP Special
« Last post by Rockburner on August 02, 2026, 06:52:13 PM »
There's always more to learn....

Last night I left a clean bit of newspaper under the bike after I'd run it up briefly.


This morning....


I'm pretty sure the culprit is the pump , which is not a surprise at all.


But it's only a dribble, it's livable with for now.

Today's plan was to get a few more miles on the bike, by visiting a Cars&Coffee about 20 miles away, then heading over to the Selsey RNLI charity event.
First I topped up the oil and petrol


And while I was at it I spread a little silicon into the Monza cap rubbers


Then set off, not without a little trepidation I have to admit!

But the bike is transformed! Fuelling at pretty much any throttle opening as pretty damned good!  :banana-wrench:  :banana-wrench:
So many thanks to the guys who pointed me in the right direction!  :obscene-drinkingcheers:

It does have a tendency to spit a touch after a prolonged period of constant small throttle opening (ie 30 zones and following dawdlers...), but once you get "on it" it's fine!

There's still a dribble of oil escaping from the push rod tube (inlet), but it was only a dribble.


On the way back towards Selsey, I even got lucky enough to get an empty bit of smooth tarmac and wound it right open!  :angelic-green:


Chin on tank..... The needle crept round the dial...

68...

69...

70…

..

71!


72!


...


73!


:lol:

Flat out is maybe 75 on the Smiths! :lol:


But the engine felt happy doing it!


Obviously though, by the time I got back towards the coast roads, the traffic built up and it was back to pootling along at 40....  :roll: yawn.

The vehicle gathering at Selsey was (tbh) a little quiet,



The ride home was more pootling, which the bike still doesn't like, letting me know with the occasional spit and hesitancy, so I decided to try and give it a bit more of a go by hitting the A27 just for a junction.

And got a bit of a shock.  I'd just wound it open again when the thing died on me! It felt like either fuel station or lack of spark, then it picked up, then died, then struggled on again....

By which time I'd reached the next roundabout and peeled off for home.

Very odd.

The engine was fine again at low speed, then I got lucky again and had a clear run to the house, so I opened it up for about 300 yards then cut the engine to roll into the driveway on a dead engine.

The result. Black, but dry, the insulator isn't completely black.


I need to review the plug condition photos, but I don't think it's that far off...
Just need to figure out if it's a tad rich, or a tad lean.

When I had it WFO previously I did try easing off a tad a couple of times, and the engine just seemed to roll off, rather than gaining or complaining.

More testing required methinks.

Note to self... Top up the oil on the side stand!

Obviously, the bike was parked on its side stand during the afternoon, and I think it started dribbling then, because the was a stain on the thigh of my trousers....

I also remembered that I had Sealey pressure testing kit, so took the opportunity to check the compression while the engine was hot.



Hmmmmm, that's actually a little lower than I was expecting...


I should have checked it the last time I took it out, to establish an early baseline.  I think I'm going do the compression ratio test soon, so we'll see.
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British Bikes / Re: Troubleshooting a JAP Special
« Last post by Rockburner on August 01, 2026, 09:48:37 PM »
So this carb stuff has been playing on my mind, so I blagged an hour today and nipped into the workshop.

First job was to fit the replacement jubilee on the oil return feed


I then reviewed the Amal Concentric rebuild guide, (which I've read a couple of times now...) and specifically looked for information and photos of the component parts, and there's a lot of information in there. https://amalcarb.co.uk/technical/rebuilding-mark-1-concentric-carburetter

First I wanted to reassure myself that the carb for a 4-stroke:
Confirmed!


Then stripped the jet block from the body.


And pulled the needle out.
It's the right length (near enough)


But, these two jets, are (according to the info in that link) for 2-strokes.
The 107 is the one I pulled out of the carb yesterday and (iirc) was the one it came with.


These 3 are correct 4-stroke needle jets (all 106)


I am rather confused as to how I've ended up with 2-stroke bits tbh.

So I replaced the needle jet with a correct 4-stroke 106 jet and kept the 206 main I'd already fitted.


The needle jet stays on the middle notch, but cross-refencing to the Amal information, it's the one with 2 grooves, which is the correct part.

Stuck the needle back into the slide (it's a 3.5), and refitted that into the body


Refitting the jet block, with the needle already in position it means there's no buggering about trying to fit the needle into the jet block of it's in situ.


The needle pulls to the right slightly at WFO, but it doesn't seem to affect slide movement.


All back together again. :D


As I was tidying up I found a brand new 260 main! But I want to change only one thing at a time, so that might be the next thing to try if there are issues at full throttle (which is the only part of the throttle range where the main jet has an effect)


I replaced the tank strap


Checked the oil again now it's cool, roughly the same as before


I then went to fire it up but fuel wasn't coming through, I poked about a bit then realised that the fuel tap was being fouled by the jubilee clip on the pipe!
Little details...


So I tweaked the tap because it had rotated a bit in the tank fitting


I refitted the 90 degree union and turned it away from the tap a bit.



THEN I could fire it up again! :D
I still can't believe how easy this thing is to start.
Everything seemed ok, and in the 5 minutes of idling there didn't seem to be any leakage from the push rod tubes. :)
The pump action is mesmerising...
https://youtu.be/zavcxQrl1vQ?is=NHoJ1tWF2tlLldTZ

Hopefully going to get out for another longer ride tomorrow. :D
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