Engine restoration....Page 1 2 3

There's too many pics to put up on the site, so I posted a few on the following pages..

My dad and I completely disassembled the engine down to the last nut and bolt. All fasteners were replaced or re-plated. I made a home-made video to help remember where everything went. When we tried to play it back, it sort of went.."Right, this bolt goes in this ..F@*$ing hole ...Balls...I dropped it..hold on dad, no dont point the bloody thing down on the floor..Jesus wept..Ahhh - its under your bloody shoe!.............................have we got another one of those?" etc..etc. We could only play it back without any kids in the room!

The Crank seemed fine when measured - so I just fitted outer seals. Probably a wrong move, should have split it and changed the inner seals right then. However, there was no play in the rods and as it turned out, the bike ran fine. No sign of any rumble or smoke etc. Still got the inner seals - just in case!!!The cases, heads and barrels all went away for welding. A couple of fins had broken. When they came back, away they went again for blasting.While the cases were away, I made a home-made oil mod to increase the tranny capacity from 1200cc to 1400cc as it wasn't worth missing the opportunity. See pic and link.............................. http://www.ozebook.com/compendium/t500_files/oilmod.htm

The Carbs were vapour blasted and fitted with new Main jets as the previous owner had changed them. The choke linkage was re-plated and the gaskets were renewed. I stripped the foam liner from the airbox, had it re-painted and re-lined it with some custom foam from L.J.Miers. The air filter was shot so I replaced it. A NOS rubber air outlet rubber completed it.

The carb rubber inlet stubs were shot and were replaced as were the stub bolts that secure them. Both inlet and outlet clamps were NOS replacements.

The alternator lead PVC cable covering had cracked and a couple of hours splicing the leads and re-fitting a new cover was well worth it.

Final assembly day came, the sun shone, the birds sang, we sang and we put it together twice after missing a washer inside the clutch. Still, practise makes perfect. It took three of us to put it into the frame as we didn't have any lifting tackle. We lined the frame with rags and pulled them out after - one at a time like watching a magician pull a tablecloth away without smashing the plates. DONE.

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Material Copyright ©2005 M.Fortune