Stuck in gear?

[Descolada]

Is it that black thing on the left-hand side - the chain looks to be all on one side and not fed around the thing the way the other (opposite side) is? Did you forget to feed the chain through?

Thing  = 'guide' ?

[mjc506]

No, that's all OK - the black thing is indeed a chain guide, but there is another that gets slotted in before the heads go in - the chain then runs between them.

Next guess?

[Juvecu]

Oil pump(?) is still on the table

[Strommer]

No engine side piston seals?

[Descolada]

This is just about everything I ever wanted to take a look inside on a v-strom. A Great current and future resource.

[mjc506]

Oil pump(?) is still on the table

Ach, you made me panic then. I think you're looking at the starter motor? But you are close - I didn't fit the water pump to the clutch cover before I fitted it!

A bit more progress tonight, though not as much as I'd hoped as I had to remove/fit the clutch cover again

Clutch cover removed, and masked.


and after a bit of paint


I didn't really take many photos of the next bits - all pretty simple, but I needed both hands, and needed to assemble quickly as the silicone gasket stuff was drying!

Cylinders on


Water pump and clutch cover fitted


Heads fitted!


Camshafts/timing next. I will take plenty of photos of this bit, as it'll be more useful to someone I'd imagine

[Juvecu]

In your earlier post, what's the thing with the two gears and a "pipe" in the middle in the 5th photo? It's at the end of your ratchet handle, next to the plastic cap.

[mjc506]

Ahhh, that's the starter idler gear. I forgot to take a photo of that installed, I'll pull the gen cover off and do that tomorrow.

edit: actually, that's a lie. Here's one I made earlier
This is removed either just before or just after the startermotor - I had to remove it as I couldn't get the generator off the crankshaft, and it was the only way of getting to one of the crankcase bolts.

[Descolada]

What are you using to spray the casing. Is it Hammerite or some equivelant?

I had to do this recently in situ to correct some corrosion/flaking around the water pump inlet (After reading comments on the difficulties removing the pump housing I was just to chicken to take that on). I masked the entire area around the pump and then used about 5 coats of Hammerite Smooth.

Have to say I was pretty pleased with the results.

[Jacko]

Looks pretty good in the pic.

[mjc506]

That's very nice!

I've gone for a strange mixture - Hammerite Smooth black on the oil cooler, radiator (sides), starter motor, and a few other bits and pieces, and Techcote high temperature satin black for the bulk of the engine. Seems to bring up a nice smooth 'sheeny' finish and it's nice and easy to apply. 24hr cure, and a slow lowish temp final cure should make it rock hard!

...should :eusa-pray:

[Descolada]

It's a very nice finish on the engine casing. I thought it looked either Titanium or 'gunmetal' - very interesting to hear about the high temp paint. Last time I used that stuff it was on the downpipe of my last bike. It didn't do too bad a job but you had to run the engine in small bursts in order to 'bake' the stuff on. Of course, doing it on the downpipe meant that wasn't a problem :-)

I also had to clean off and respray my radiator because it had started to bubble at the corners. I dug off all the older damaged paint only to find a paste mix under the bubble that seemed to be made up of salt and water. Nasty stuff, especially as it was still liquid and so active.

I cleaned it all off and gave it 5 coats of Hammerite Black smooth, the end sections only mind you, nothing went on the cooling fins in between. All this talk of High Temp paint has got me worrying that the Hammerite might not work out over time and successive heating and cooling cycles. I have to say, now I have the hang of getting the radiator off and back on I could take it all off again should the new paint start to corrode, but cleaning it off was a paint in the proverbial. I wouldn't look forward to doing that again so soon :-(

[mjc506]

Hammerite should be fine on the radiator - worst case temp should be ~100degC, well within normal paint capabilities. The engine does get a little hotter though, so...

Scant progress this weekend. Got the timing sorted (and turned it over a few times with the wrench - no grinding noises! ) but measuring the valve clearances showed all four exhaust valves over-tight. New shims ordered, should have then by tomorrow. I was about to go off in a rant about how the garage can't have checked them, but then realised that the last service they did included the valve check, and that was ~35k miles ago... I guess the clearances could have changed since then

Set up the timing mark to 'F' on the generator. Make sure to turn the crankshaft anti clockwise (facing it from the lhs of the engine). It is essential to keep both cam chains tight!


Each camshaft is labelled, so if you failed to keep everything organised, it's not the end of the world. For example: Inlet Rear:

and Exhaust Rear:

Follow the service manual religiously. This is the front cylinder timing marks:

Note, in this photo, you can't see the '3' mark. It is there, but faint, even in the flesh.

Cover the journals in engine oil!


Journal's fitted in place:


Tensioner installed:


And then do something similar at the back! (but make sure that you follow the manual re: timing marks and crankshaft position!)

It turns!


And here I am double checking tappet sizes...

[iansoady]

Nice to see you using an imperial mic!

I have to say I almost always use my cheap digital caliper (<£10 from Maplins) these days as it seems just as accurate and is easier to use.

[mjc506]

If I had a choice (read: if I could be bothered to order one), I'd use a metric one! That said, this one was given to me by my grandad, it's at least 30 years old, and last time it was sent for calibration it needed nothing doing to it! Granted, it's hardly used, but even so...

[MartinW]

Great photo's. Thanks for reporting on all of this. I'm still impressed that you are still working in the garden.

[mjc506]

The engine's now spending tonight in the front room

note for next time - it's silly heavy. Don't try and carry it across a tiled kitchen in boots covered in oil, soap and water... :limp:

[mjc506]

It's all in one piece!!!

Fitting the new tappet shims:

and now the valve clearances are all good

and a crappy photo (taking a picture of a shiny black thing in low light with a mobile phone is never going to work great...) of the first few coats of satin black!


I'll get a daylight picture shortly

[Juvecu]

Looking forward to the better pics

[mjc506]

a bit better:


Definitely another few coats needed, after a rub down but I quite like the finish. Whether or not it looks right on the bike is another matter of course