Tim's Seized 500 Engine Rebuild

[Minter]

It was all I had about. I would have put bits up the front with a brace across the top (like the back) they would have made handles.
Could do with a drip tray in the base then it could all be wraped in cling film for shipping.

Pete

Brace fits perfect into some big green boxes ive got, that should contain any leaks etc and provide added protection, you'll no doubt get to see one soon!

[Minter]

...I reckon it could be time for Gary to give up the day job & enter the wonderful world of self-employment!.....Go on Gary!....

you never know John! We'll call it a weekend job for now and see how things go! I need to go back to work in the week for a rest!

[timbradder]

Yes I think my engine is in good hands

[Minter]

Important bits arrived for Tims motor, new liner and piston, liner away being fitted to original cylinder. Now the work can begin to get this motor back up and running!

[danswankie]

i never knew the liner could be sourced as a seperate item i thought that it was moulded into the aluminium part of the cylinder ...was this an expensive part if you dont mind me asking ?

[Minter]

Hi Dan its not expensive compared to the piston but the pressing out of the old and pressing in of the new is! Then it has to be bored and honed to match the piston as its only a rough finish inside. As oversized pistons have run out and waiting to be manufactured its the only option as there are plenty of liners and standard pistons.

[Minter]

Ive managed to do a bit more to Tim's motor this week whilst the new Liner is away being fitted..



Most of the oil and crud removed..



Sump wasnt a pretty site!



I'll give the gearbox a lick of heat resistant paint for you Tim..



Bottom pully looks a bit sad..

Good news is Gearbox and Crank all work a treat and hopefully i'll have the cylinder back on Xmas eve....

[timbradder]

Thanks mate the frame has been sand blasted and taken with the plastics and other bits to be painted so hopefully it wont be long before I can start the rebuild so far I know I need yolk and swinging arm bearings which I have sourced on here along with complete set of stainless bolts not found handlebar controls yet or new wiring harness but may use old harness

[Minter]

Done a bit more to Tim's motor this evening, even given the gearbox a lick of paint!





Head stripped and cleaned up a bit, should get, head and clutch built back up tomorrow now.. just waiting for a call from the engineering firm who has got the cylinder..





Shouldnt be long now Tim!

[Minter]

Still waiting for the Cylinder to be relined, so rebuilt the clutch and various other bits and bobs this avo..

Kick start return spring put back together..


Then the clutch and all associated cogs.. Clutch basket has had all the grooves filed down


Nice clean sump with new O rings and gaskets


Then a new clutch went in.. Steels were all fine and have been reused.. New lock washer and torqued to 120Nm!


Clutch cover has seen better days due to corrosion inside and outside! Must have been a lot of water inside! I'll have to build up some of the case with JB weld so that the timing cover fits tight..


Plenty of corrosion this side of the motor too..


Nowt a lick of paint wont fix though!!