Malmesbury Nick's CV500e Engine Rebuild

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The other week Nick popped over with his CV500e engine.. Here's the progress so far pulling it apart..





A nice new 604 starter motor fitted..



Flywheel wasnt held on and the trigger coil is missing..



Timing gear has seen better days but the bottom pulley should be salvageable..
No threads for the crank locking bolt so that will have to be helicoiled..



Plenty of scrap in the bottom of the clutch case, looks like bits off the old clutch plates tho..



Looks like someone has had a go at rebuilding it but it never ran!



Sprag was missing the circlip and the bush in the centre was wrong way around flattening the the woodruf key. Sprag spring was well stretched and all the lobes just fell out once it was removed! They are ok though and not much brinelleing to the gears..



Over sized piston and bore but all three rings standard size! Cylinder should hone out ok..

This motor will be getting the full monty treatment for Nick, so should look good and run like new when its done..

Should keep me busy for a week or two!

[nick]

Good to know its in excellent hands Gary
Progress is coming along slowly but steadily with the frame and other parts, and I'm looking forward to putting this bike back to how it should be.
I'm still slightly torn about whether to restore her to original (as possible) or to make her a bit of a hybrid (disc front end, 350 bark busters, twin seat etc...)
One thing I'm sure of is that I'll need plenty of help when it comes to the electrickery side of things....
This is not gonna be a quick project, but it will be a bike I'm going to keep for the long term....

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Motor stripped down to just the cases today ready for powder coating..



Engine finally came apart some of the crank case bolts were proper seized and had to be drilled out.



Crank case seperating tool doubles up as a crank shaft pusher tool too..



Slide hammer used to pull out the blind bearings..

Ive another to do tomorrow then both off to the powder coaters..

[nick]

Good work Gary. Thanks for posting the pictures, it's good to take a sneak peak at her internals....
I was reminded of why I don't do this sort of mechanical 'surgery' yesterday ... My coffee machine broke - the grinder stopped working. So I went on line, and found a coffee geek in Indiana who had had the same issue and photographed his method of fixing it.
I took the thing to pieces, did the necessary, and put tall back together again. It works fine, but I have one screw, one spring and a ball bearing left over - no idea at all where they belong...
It doesn't matter so much in a coffee grinder because it's not propelling me down the road at 80mph !

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Good work Gary. Thanks for posting the pictures, it's good to take a sneak peak at her internals....
I was reminded of why I don't do this sort of mechanical 'surgery' yesterday ... My coffee machine broke - the grinder stopped working. So I went on line, and found a coffee geek in Indiana who had had the same issue and photographed his method of fixing it.
I took the thing to pieces, did the necessary, and put tall back together again. It works fine, but I have one screw, one spring and a ball bearing left over - no idea at all where they belong...
It doesn't matter so much in a coffee grinder because it's not propelling me down the road at 80mph !

Cheers Nick, This one would never have propelled you down the road in the state it was in! Its been split before in its life and there must be plenty of bits from it left on someone else's work bench! It'll be just as Rotax intended in a few more weeks!

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All cases ready for powder coating..



Cylinder head has been damaged in the past.. blind cam bearing has been pushed all the way through at some point.. this will be an interesting one to make oil tight...



Cylinder liner has a deep rust mark that wont hone out, new liner being fitted..

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UPDATE:

Cases all at the powder coaters.. Should have them back soon looking like new!

[nick]

Brilliant work Gary! There is no way I would have able to resuscitate the engine by the look of it.... How did you get on with the cam bearing buggery?
Can't wait to see it looking beautiful..... and then to hear it firing up for the first time
Slow but steady progress with the frame... she's getting there

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Chees Nick.. I have a plan for the cam bearing!

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UPDATE:!

Collecting all powdercoated cases next Thursday (31st) evening.. Plan is to rebuild on Sat 2nd Nov.. Hopefully cylinder will be rebored by then too..

Watch this space!....