New heart for the old girl

[allankelly1]

Hi all

Always was planning to rebuild the engine on  my old girl as the “last piece” of the jigsaw



Trouble is it’s never a “good time” to do it with a running bike so decided to buy another engine so I can do the work without the old girl being off the road too long

So picked up this today from Ted ( many thanks again Ted)



Now it’s home and as it’s a “no rush” build going to not just do a rebuild but planning to do possible the following changes as well as a complete rebuild from the sump bolt to the top of the rocker box

Take it up to 460cc
Yoshi stage 1 cam
Get the head ported and sorted and  possibly swap to Amal smoothbores and pods

And no doubt a few other internal tweaks too as been reading you can update the oil pump to a GL1000 with a modified oil pump housing?

Once done should be a special bike with some nice additions

Lastly no doubt along the way I will be asking lots of questions but first off need to build a engine cradle so the motor will sit nicely on the bench as it a bit more heavy than the RDLC engines I have built in the past so don’t fancy it falling over

Catch up with you all soon

Best wishes Al


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[4wDaz]

Nice 1, any broken fins ? even has the rare kickstart 

[allankelly1]

Yes no broken fins

As for kick starter I had one spare as with Raask rearsets on my old girl you cannot have a kicker so fitted this to see if it spun over which it does


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[McCabe-Thiele (Ted)]

Yes no broken fins

As for kick starter I had one spare as with Raask rearsets on my old girl you cannot have a kicker so fitted this to see if it spun over which it does


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Sounds like the ATF I put down the plug holes has worked!

[allankelly1]

Yes it looks good for my first initial peek inside.

Had a look at the cam and the bearing journals it runs in as I read somewhere that infrequent oil / filter changes cause this area to become scored and all looks ok







So that I hope bodes well for the rest of the insides including crank and box

Best wishes Al


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[K2-K6]

A nice project with time to complete it in parallel while the original is being used.

The bearings do indeed look quite good.

Failed oil film(old or diluted with fuel) would ordinarily cause the camshaft to wear the aluminium bearing surfaces and perhaps bring pickup and degradation of the rocker faces.

Unfiltered oil with abrasive particles ( metallic or grit based) would be embedded into the soft aluminium and cut the steel camshaft bearings. 

Neither look to be the case, suggesting it's been serviced at least competently in its life regarding oil changing etc. Quite a good start.

[McCabe-Thiele (Ted)]

Looks very good considering its been stood for a long time a testimony to dry storage I guess.

[allankelly1]

Ok

That’s the first stage done.

Engine now sat in a custom engine cradle
 

Now to drain her out and then a carefully strip down with tons of photo as a reference point later when I have forgotten how something fits

Best wishes Al


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[McCabe-Thiele (Ted)]

Hi Al,
The oil is proper mineral oil so might be handy to put back in later - the small amount of ATF oil I put down the bores will not cause any issues as its amazingly versatile stuff. Back in the late 1990's as a cure for Astra layshaft noises the Vauxhall fix was to drop the Hypoid 80 & use ATF Dexron 2. That is Dexron 3 fully synthetic I used.

[allankelly1]

Hi all

Cracking on with the strip now

Generator rotor off, clutch basket off with my home made puller and clutch nut peg spanner,  and barrels now lifted too






Cam chain tensioner has done its normal siezed up solid and snapped off and found out on stripping down the engine the clutch side has a damaged lug




But once the cases are bare these jobs will be easy to do as I will do the normal tensioner upgrade and fit the upgraded  stainless steel tensioner assembly and get the broken lug built up by my local TIG welder expert and retapped

Catch up with you all soon

Best wishes Al


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[McCabe-Thiele (Ted)]

Shame about the damaged clutch casing lug - wonder if it was done when the bike was dropped sometime in the past?
Never knew the story behind Pops frame damage - rot or accident?

[Johnny4428]

That’s one cruddy looking engine! Nice to get right inside to see the state of things.

[allankelly1]

Nice and tidy inside

Best wishes Al





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[allankelly1]

Shame about the damaged clutch casing lug - wonder if it was done when the bike was dropped sometime in the past?
Never knew the story behind Pops frame damage - rot or accident?

Hi Ted

Normal stuff for a 40year plus engine

Got a local TIG welder that repairs stuff like this so it will be as good as new when finished

Best wishes Al


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[McCabe-Thiele (Ted)]

Those gear clusters look remarkably free of surface rust - mine had quite a bit especially around the gear dogs.