Freshening up...

I replaced the friction plates and deglazed the steels in my clutch not long before I tore my engine down, so I pulled them out of the old engine and put them into the new one:



Lapped my valves:



Shimming the head...







Some tools that make it a much easier operation:







I redisassembled my head, then rereassembled it with just the right amount of molybdenum disulphide in just the right places:





Next up, slugs & jugs!



I need to hone the cylinders and maybe polish my piston skirts. I had planned to use Action Man's cylinder hone, but he thinks I'm trying to kill him so that means I have to buy a cylinder hone. I'll also have to buy or rent or borrow a torque wrench...





Hey look, it's art!

Let's say you only have one ring compressor. How do you get all four pistons in all four cylinders and attached to the connecting rods?









This is an extremely ticklish operation, and I had to undo and redo it a couple times. By this point I was shaking from the tension (medication makes it worse), and then I dropped a wrist pin retainer clip down into the crank case and felt my blood pressure spike, hahahaha!

I went outside and walked around for a few minutes, did some deep breathing, then went back and pulled the block off, pulled the pistons and fished around in the case with my handy telescoping magnet for about 15 minutes until I heard this little tink.



Sometimes you have to get away from something before you start throwing tools or make a mistake, so I'm on break. I came inside and watched Squidbillies, ate some beans, now I'm gonna lay down for a little while, then go back out and try again.

A little while later...

They should make this into a movie:)
Fascinating to watch,keep it up!

guitargeek, Yep, been there, done that. What really pisses me off after I drop a circlip in the crankcase, is when I look in the manual and it warns about stuffing shop towels in the openings to prevent such silly things from happening. (Slow burn with blood pressure peaking) Please keep the story coming to us, Steve

Tried the rag thing, but there's no room to remove the rags after attaching pistons 1 & 4, just have to be super careful.

I got a lot done today!

guitargeek, I was planning on using the same method to fit my 500 engine [lay the frame over the lump], just how much grunting and scratching did you do?
Would it be easier using a mattress?

SPARKY47 wrote:

guitargeek, I was planning on using the same method to fit my 500 engine [lay the frame over the lump], just how much grunting and scratching did you do?

It wasn't bad at all. Hardest part was moving the engine from the milk crate to the floor. Everything after was gravy, just go slow.

Would it be easier using a mattress?

No.

You'll need to shim the engine up with some some wood scraps or paperback novels or Duran Duran CDs or something so it's level. If you put the engine on a mattress, it'd just sink into the mattress and you'd have a hard time bolting up the frame...

Thanks for your answer, I thought a mattress was the way to go, now I know better. Even though its "only" a 500, its still f****** heavy [75kgs], 165 lbs to you youngsters in the new world.
Alas, no duran cd's[that was simon le bollock wasn't it?].
Did you know?[as an aside to everything, that the silly ******* took a boat out and upended it? Had to be rescued...twilluck.
repeating itself AGAIN....TUT TUT.

Progerse!

Did you istall pistons in to sleeves first and then connected pin/rod:ohmy: I´ve never heard it done that way but if it worked it´s just the same. It´s just a huge risk of dropping something into crankcase....

@ guitargeek...

Love where this project is going...
Keep posting the images.

Question, since you had the motor out of the frame, was there a reason not to clean it up (wire wheel, buff, paint)?

Not really any of my business, your bike so feel free to tell me to go screw myself LOL!... Just curious...

OMR