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Post by buster on Mar 5, 2022 15:33:08 GMT
so quick recap, I snagged this motor for just under £65, it was only 25 miles from me so I felt well worth a punt. first job drain the oil  if I hadnt already decided to build this engine then seeing this disgusting horrible gloop would have forced my hand. wonders will never cease, this is the first time I'v ever managed to get all 8 cylinder bolts out intact, threads to inspect later  so head off and I'm now really glad I didnt try and fire it up  I mean really, really, really glad I didnt try to fire it up   |
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Post by buster on Mar 5, 2022 15:46:49 GMT
this is going to be hard to believe but I'm quietly optimistic that those barrels will rescue, I gave them a wipe out and had a really good feel inside and theres nothing bothering me (yet) the hone will tell. meanwhile check out the ring gap, god I love these motors  might be worth mentioning that when I strip a motor I often reassemble components as I go, that way I dont lose anything  the rings might take a bit of shifting  oh dear, first bit of bad news, I suspect I know what this is on the ear trumpet   bugger! suspicion confirmed  for those that dont recognise this its the piece of alloy casting on the bridge piece that stops the cam chain falling off the crank sprocket during assembly. this is a bit of a PITA, two options, 1 get it welded back on, 2 I think I have a spare top case/bridge so I'll probably use that, another bonus with using the spare is its from an earlier japanese model rather than a brazilian. so its now as stripped as it needs to be until I get some degreaser to it  |
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Post by CTB on Mar 5, 2022 16:52:38 GMT
Jesus Buster you don’t mess about, I spent more time contemplating than doing by the look of things 😆
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Post by duffer on Mar 5, 2022 17:43:21 GMT
Jesus Buster you don’t mess about, I spent more time contemplating than doing by the look of things 😆 I can confirm his story buster.... |
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Post by tucksie on Mar 5, 2022 18:45:29 GMT
Following your work is an education buster. Very interesting.
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Post by buster on Mar 5, 2022 19:18:42 GMT
Jesus Buster you don’t mess about, I spent more time contemplating than doing by the look of things 😆 I think its about what your confident with, you get a whole bike back together while I'm still farting about with engines |
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Post by robinbanks on Mar 5, 2022 19:32:14 GMT
Great thread that gives us all the confidence we need to tackle such jobs I think.
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Post by buster on Mar 6, 2022 12:39:43 GMT
clean and inspect the crank, all looking good, its actually on brown big end shells and I have a set of NOS ones so they will be fitted. main bearing shells look pretty good, all I'll do is swap the stator end shells with the middle shells (same code).  time consuming fart about job (do it too many times and the threads wont take it) but worth it because I want those cylinder bolts to tighten up as evenly and nicely as possible  |
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Post by buster on Mar 6, 2022 15:57:45 GMT
so lots of cleaning, the new crank cases have come up almost like NOS and they're in great shape, I'd guess they came off an american toy, buy it, ride it for one season and park it and forget about it  the only fly in the ointment so far is this gear on the layshaft, happily I have a spare from my old 450 nighthawk engine (part numbers match) I'll also probably change the single selector fork as its showing a bit of wear  |
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Post by duffer on Mar 6, 2022 18:10:09 GMT
Fearless. Love it. If your workshop doesn't have a sign "How hard can it be ?" then you should get one.
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Post by buster on Mar 11, 2022 14:15:04 GMT
so gearbox sorted with a replacement cog and nice new seals  then the fiddly bit, I fit the rear balance weight on its shaft with its nice new chain then ease the slipper guide into position and secure it finger tight on the front bolt only. its then a case of lining the crank web up with the top engine casing joint and fitting the bridge piece with the balance weight in the right position, oddly I got it first time on this engine, then scratched my head for 5 minutes wondering what I'd got wrong . once the rear weight is positioned and correct I pop a couple of bolts in the bridge and finger tighten them down so the timing cant slip, your then free to mess about with the front weight until its in the correct position.  a new fly in the ointment, the brazilian ear trumpet has a different size spigot on it (18mm) and it wont fit the 16mm hole in the bridge, I'll have to check my spares, hopefully I'll have one  |
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Post by buster on Mar 12, 2022 15:40:53 GMT
I thought I had a spare ear trumpet but i'm blowed if I can find it, so robbed one off the cafe racer engine  then a thin smear of wurth engine sealer and join the crank case halves  next fly in the ointment, someone had chipped the oil filter housing (and to get it to seal tightened it with big bar) I have a spare but it needs paint, so the next bit of the build is upside down  possibly the most important job, prime the oil pump before fitting, oddly this gasket set didnt come with an oil pump gasket but I tend to think they're something of a sacrificial part anyway. they are unbelievably thin and I'v never found evidence of them when stripping an engine down  then dismantle the clutch (plates were well seized), clean and rebuild with a film of fresh oil on each plate, its all loosely back together at the moment as I need to flip the motor to lock it off for tightening up   |
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Post by buster on Mar 13, 2022 16:51:42 GMT
time to strip the cylinder head, I'm probably over pedantic with this but each valve and its components are numbered and bagged and everything goes back (eventually) where it was. worth adding this head looks, on first inspection, to be pretty good, I'v saved far worse  |
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Post by buster on Mar 19, 2022 9:12:11 GMT
damn, just suffered the first setback, the piston rings I ordered from japan havent arrived. I got an email on thursday saying that they had been delivered, so checked the letterbox, checked the cat flap (you'd be surprised how many people think its a letterbox), checked the log stores and checked with the neighbours all to no avail. so I emailed the seller in japan to see if they could track them down and they sent me a refund? its a bit of a problem too as thats the only ebay listing for suitable piston rings  , so onto the net and ordered some from an american firm, I'll probably get stung for the import duty (no problem with that) and the obscene handling charge. oh well lots of other stuff to do |
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Post by buster on Mar 26, 2022 16:14:51 GMT
still waiting for piston rings (I'v got two sets coming now, as I saw some NOS ones on ebay) so onto the cylinder head. first job de-coke the exhaust ports  this head was cast in fairly new sand (it was pretty sharp) so the inlet ports have that nice texture to them, they will just be cleaned. next job is to revive the valve seats  perhaps a little more contact area than I'd like but I'll sacrifice that for a good seal. this kit is great for slightly dodgy old heads and really cuts down on lapping time  and finally a load of elbow grease applied to the combustion chambers  |
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, so onto the net and ordered some from an american firm, I'll probably get stung for the import duty (no problem with that) and the obscene handling charge. oh well lots of other stuff to do