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components
Christmas Break 15 hours Photos 46 - 48
I did not spend as long as hoped over the Christmas break and work was
mainly confined to organising the parts in the garage, cleaning and
inspecting. The Engine block, gearbox / shaft assembly and head were all
cleaned and the timing cover had broken studs drilled out one of which
proved really stubborn and the case will need a small amount of alloy welding.
The Cylinder head was also stripped and the valves cleaned. Tappets were
measured prior to removing cams so it can be reassembled with the correct
shims.
4th January 05 1 hours Photo 49
Exhaust and inlet ports were cleaned Parts ordered from Motobins.
5th January 05 2 hours
The Clutch mounting plate was removed and the last of the torx screws
holding the bell housing drilled out. The bell housing was removed to reveal
the starter gears. On inspection these seem to work fine so I assume the
sprag clutch had jammed when starting the bike but freed itself while the
engine was being dismantled. The damaged screws were removed with no
damage to the threads.
2 of the 8 valves were also ground in.
9th January 05 3 hours Photos 50 - 53
The remainder of the valves were ground and I realised checking clearances
was not necessary as disturbing and grinding the valves would mean they
have changed anyway! New seals were fitted and the valves and springs
assembled. The oil / water pump and remaining items on the engine block
were removed, cleaned and sprayed black. The crankshaft was refitted with
the new main bearings. One piston was refitted with new rings and big end
shells. This was difficult to locate the new rings into the bore so I rechecked
the end gap which was ok, closer inspection of the ring groves revealed build
up of hard carbon that had not been removed with the normal cleaning and
had to be cleaned with careful use of a hacksaw blade. The piston then fitted
fine and the engine turned smoothly.
12th January 05 2 hours
I need to get the things to the powder coaters tomorrow and have also had
the chance to get the bodywork sprayed so I needed to locate all relevant
parts and remove badges and fittings.
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| Parts fro powder coating |
Parts for spraying are |
| Frame Cam Cover Sump Cover Timing Cover Ignition Cover Stand Assembly Speedo Base Plate Rack Radiator Surround Radiator mesh |
Main Fairing Lower Fairings x 2 Fork Shield Radiator Cowl Side Covers x 2 Mirror Covers x 2 Petrol Tank Front Mudguard Rear Seat Surround |
13th January 05 0 hours
Parts taken to CMF All parts to be sandblasted and coated - Silver on engine
casings will have to be added with silver paint or by removing coating and
then lacquering.
Went to Baker Street and gave Graham Body work items, he’ll let me know
cost once he’s seen peter at Cowlins.
13th January 05 1 hour
Cleaned and fitted remaining 3 pistons and bigends - engine turns fine, just a
little tight by hand but very smooth.
14th January 05 1 hour
Fitted transfer shaft.
17th January 05 0 hours
Extra O rings turned up.
20th January 05 11/2 hours
Collected Powder coated parts on way home from work - no charge but gave
them £20 as a thank you.. Had a feeling the transfer shaft was not fitted
properly, it turned OK but something was nagging at the back of my mind so I
removed the housing and found that the circlip at the water pump end was not
located in its slot - would have been expensive if I’d left it! Refitted shaft and
fitted water pump housing and cover. Fitted cylinder head and torqued to
correct setting. Got a lot done in 1 ½ hours.
21st January 05 2 hours
Fitted cam followers, shims and cams. Checked clearances
22nd January 05 5 hours Photos 54 - 61
Timing chain and components refitted, clutch housing and clutch replaced, all
engine covers fitted. Engine now only needs ignition oil seal and pickup to be
fitted and them it’s complete.
23rd January 05 2 hours
Tried removing swinging arm but bearings are seized.
24th January 05 1 1/2 hours
Had stubs drilled out at work to free swinging arm. Removed bearing outers
by grinding. Refitted gearbox and checked clutch operation. Removed neutral
switch for checking and left gearbox to drain oil over night.
26th January 05 1 1/2 hours Photo 62
Swinging arm bits and head bearings arrived. Fitted front oil seal and refitted
ignition pick up using bolt marks for initial timing. Drilled and taped repaired
area of timing chain cover and fitted ignition cover. Cleaned and fitted inlet
stubs - these are sealed ok and have no cracks but from an appearance point
of view should be replaced at some point, although very little is visible once
fairing is on. Cleaned and fitted water hose and temperature sensor manifold
with new O ring.
28th January 05 1 1/2 hours
Fitted stand assembly and place engine back on ground. Refurbished
injectors and injector rail and refitted to engine with new O rings. Fitted
throttle Bodies.
30th January 05 3 hours Photo 63 - 65
Replaced swinging arm bearings and greased drive shaft. Refitted swinging
arm with new stubs. Repaired air box mounting thread and fitted lower box.
Positioned frame over engine and bolted in place.
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