I'm doing the engine bottom end overhaul for Ed, he's already got the rolling chassis and a beautifully painted tank, plus a bunch of chromed stuff and new parts (some on the chassis already). The cylinders were already bored, and a full valve job done on the head (head, cylinders & rockerboxes are painted).
I picked the engine up a few weeks ago, and finally got time to tear it all apart (top end was in place loosely), wash everything, inspect and measure the wear parts, and come up with a parts list.
So, here is the photo shoot from the tear-down...
Rockerboxes were set in place backwards (no worries, marc)
Beautiful new valves and clean head
Grungy area around the sprocket immediately told me the bottom end hadn't been worked on.
Tranny inner cover with NON-typical sludge. Usually it's MUCH WORSE! This stuff at least looked like OIL, not gravy.
Ruh-roh Scooby, somebody had installed the driving dog backwards. Flat face is supposed to be INSIDE, to provide full contact with the driven dogs on the next cog.
One of the gear bushings was not pressed fully in place, and could have resulted in a crashed gearbox. I pressed it fully home (it was not loose within the gear, so not simply slipped out).
Primary side case slip right off, had to fill a box with shredded paper, set the timing side case half over one corner, then smack the crank nose with a mallet (of course with a piece of hardwood to protect it!) Cases were actually somewhat cleaner than is typical; still, some sludge.
Obvious signs this bottom end was delved into at some point in the past.
Cleaned up the peening on the sludge trap plug, but it refused to budge. So, I welded a large washer's i.d. onto the plug face, then welded a large nut to the washer. Let it cool, and extracted the plug with just moderate effort.
I used a chopped off spoke to slip into the bolt hole in the sludge tube, clamped the spoke with a pair of vice grips, then started tapping it out with a hammer. Only took a handful of whacks and it slipped free.
About a tablespoon full of sludge came out with manual scraping, almost as much needed to be scrubbed out with solvent and baby bottle brush.
Box full of dirty parts and a set of empty cases...
Hey GP,
I'm surprised that the piston rods don't have bronze bushings in the small ends. I guess that's normal on these bikes because my piston rods also look like the ones in your photos.
Are you concerned about the rods getting nicked up being lumped in with all those other parts to be cleaned or are you going to sand them smooth after degreasing them? I'm interested to know how far to go in cleaning up the rods in my bike....Gary
Cleaned rods & crank, lubed journals, installed shells & torqued rods. Applied a dab of loctite to the nuts after torquing, Installed crank in cases and nipped up.
Fought the clutch rubbers into their final resting places by cinching up an old clutch hub in the vice, then using my clutch locking tool to rotate the housing against the internal spider. Sure helps!
Installed new primary sprocket oiler tube, all 20 rollers in place with a touch of grease (new thrust washer behind).
Installed primary, clutch & alternator with new rubber bootie for the alternator pigtail. This side is done.
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