I had a few problems with the silencer as in a cracked bracket and a couple of stripped threads in the engine casing where it is mounted. This only came to light whilst fitting it.
So it's back off with it and a dab of weld applied.
I managed to recover one of the stripped mounting bolts by re-tapping the thread (tailpipe mount), putting in a new bolt and a dab of Loctite. Seems nice and tight.
The other stripped bolt (top mounting) has been cleaned out and the bolt loctite-ed in. It won't tighten properly but will do at this stage. There are more than enough mounting points to keep it secure. In the future, it will have to go oversize and a new thread cut. The other option is a wire thread insert, which is better done with the engine out and the chaincase removed. Pity I didn't know about the stripped thread a couple of weeks ago when the engine was still on the bench.
Anyway, the silencer is back in place now.
Moving on with the re-build, the air-box, air-filter and hose to carb are all back in place.
The air-box (between the fuel tank and the toolbox) only takes up half the width of the scooter. The other half is reserved for a tray and battery which as far as I can make out only serves a parking light. This was fitted for the UK market apparently but as it is a bit pointless here in Cyprus, I'm not going to bother with it.
That's the air scoop fitted. I wonder if that's going to get in the way of the back two seat mounting bolt, we'll see tomorrow!!
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