Stuck in gear?

[Jacko]

Try the dishwasher though, I hear Finish is good for baked on grime.

[mjc506]

I figure black is worth a go The dishwasher brought both halves up lovely, but the gold-brown effect is still there. Baked into the paint by the look of it.

Seems like the best bet will be to assemble the engine, then paint it (masking off any non-paint parts). If I'm going to tart it up, I think I'll be replacing all the clutch/generator cover bolts anyway, so that's quite a few I don't have to worry about Otherwise, I'll have to be scrupulous when masking if the engine's all apart, and I won't be able to bake it properly anyway... I'll have to research paint a bit...

[Juvecu]

I'm going for a dark grey/magnesium colour for the side cases on my engine. I think black is too much, but that's because I have a black frame.

[frez]

Black will probably show up the stone chips quicker.

[mjc506]

Black frame here too.

I think I'll give it a go, if it looks shite I can always drop the engine and do it again in silver

[mr_diver]

Someone is getting cocky now.

Loving this thread. Particularly the gratuitous open engine pics.

[mjc506]

Pretty much the end of the open heart surgery now - the crankcases are back together, with all rotating parts moving as they should Check out the colour difference between the two crankcase halves!

[MartinW]

Still stuck outside then  
It's going to be great to see you post a video of this bike being successfully restarted.

[Jacko]

Is that one of those blue folding camping tables, with the chairs attached? If it is I'm giggling, if it isn't then say it is because it's hilarious.

[Juvecu]

Ah, I misunderstood, I thought you wanted to spray the side covers, but you're on about the crank cases themselves. I'd vote for 'aluminium' then. VHT Engine Enamel "SP127 Univ. Aluminum", it's what I got to do my crank cases and the cylinder heads. I'll probably start on cleaning and spraying the engine this weekend, but I guess you wouldn't want to wait to see what it looks like before buying your paint.

[mjc506]

I want to spray everything! EVERYTHING! :hyper: and I ordered the paint late last night we'll see how it looks, but I'm still open to persuasion from photos of a beautiful engine

Jacko, I'm afraid I'll have to disappoint, I don't think a camping table would carry a cylinder head, let alone a complete engine this is actually a generous donation from my work - a hydraulic raise/lowered trolly. It'll lift 500kg, so once I'm done with this, I'll weld a decent bed onto it and use it as a bike lift

Martin, I'm terrified of that moment! Yes, it will be videoed, but I might have to take the plugs out, stick it in 6th, and push it around for a bit to make sure everything turns without horrible noises...

[Jacko]

Well that's a damned shame, I thought you were defying the laws of gravity, you'd have had convenient places to sit while working too.

Full respect due for the work.

[mjc506]

Some more progress.

Here's the lhs with covers off and most bits fitted:


and here's the rhs. Note, the oil pump is fitted, as is the gear selector mechanism and camchain/sprocket.


Now for the clutch.

Clutch basket as removed: (filthy)


...and after a quick clean:


on the engine:


'inner basket' ?


and bolted up. I have yet to bend the lock washer over here


Marvel at the difference between new clutch plates (left) and old (right, burnt)


Soak these in oil, and slot into the basket


Done!


Descolada, I've a few more photos to take (removing the clutch cover etc) and then I'll put together a clutch service how-to.

[Descolada]

Respect Man, you are doing an amazing job with this. Both with the mechanics and the documentation.  

[Juvecu]

Top stuff, mjc Loving all the good photos, proper bike porn

[mjc506]

it's more 'snuff' than 'porn', but OK

It's going far too well... I might be finished soon! You have no idea how much I hate 4 wheels at the moment :violence-uzi:

[frez]

Be worried if you have one or two bits left over after it's fully assembled  

[mjc506]

Ah, I get around that by ordering a few bits too many - that way I know I'll get some bits left over so it's not a mistake

Good progress tonight. Side covers on and pistons cleaned and fitted. Cylinders, heads, timing and valve covers tomorrow maybe!

[Juvecu]

I think you'll get to spraying the engine way before I do. Looking forward to your reports on that :banana-wrench:

[mjc506]

Good progress last night.

Removed the water pump from the clutch cover, and opened it up (I'd disturbed two of the orings while removing the clutch cover, and I had all the spares anyway, so thought I might as well). Be careful here! The two screws holding it together are tight, and JIS - use an impact tool to loosen these.

Mucky eh? Looks like I had a tiny coolant leak through one of the o-rings too.

Don't do this bit if you don't have to! This seal was a b*stard to remove. It's an incredibly tight fit, there's nowhere to pry it out, and it's also glued in. I destroyed mine on the way out, even with a good application of heat!


Note: if you do need to change this part, the spare comes in two halves. One half fits in the hole, but it took me a little while to find where the other half went:


Clutch cover gasket on!


Clutch cover temporarily fitted - I have some new shiny bolts to fit after painting.


and on the other side, here's the generator cover fitted


Here's a cleaned piston, with the rings being removed


and here they both are fitted with new rings! This step really is quite simple. Just make sure you do one at a time - and refer to the other to make sure you get the rings right. The manual isn't particularly clear which goes where, and only one is marked with a 'T' on top. I was concerned that I'd got the wrong bits, but the old rings matched my new ones. Basically, from the bottom upwards, oil ring (consisting of side ring - spacer - side ring), then the second ring (marked with a 'T' on the top side), then the first right (groove on top). Please double check this on your engine first though!




So, who spotted my "deliberate" mistake?