Chris Godspeeds 500 Jigsaw Project

[Minter]

Evening all,

Chris dropped off his boxes of bits of an MT 500 a few weeks ago! Tomorrow I'll start to put it all back together!

The engine is partially stripped and the cyl head now back from the engineers after having some very rusted in exhaust studs!

A new stainless system has arrived which will be painted black and new T63's ordered as this will be Chris's off roader!

All finished off with a new MOT ready for N Wales..

Pics to follow tomorrow.....

[Minter]

Heres the progress so far....

Engine done, needs fitting tomorrow evening, new T63's ordered and on route, MOT booked for next Saturday morning ready for chris to collect on the bank holiday and get some practice in ready for N wales!!





Whilst the head was having the rusted in exhaust studs removed i made a start on the bottom end



Crank shim wanted to escape..





Oil pump tested and working a treat..



Mullered crank keyway due to bottom pulley coming lose.. Now repaired



Piston has had a hard time prob due to lack of oil or picking up part of the crank shim.. All polished out and new rings fitted





Head back with studs removed



head cleaned up and valves reground and pressure tested - good as new...



All ready for a test run and fire back in the frame....

[Godspeed]

Huzzah!!!

[jungleMTbiker]

How do you pressure test the valves? I have had good success leak testing valves by pouring petrol into the ports (one at a time) and seeing if it leaks into the chamber, but it sounds like you are actually pressurising the chamber somehow.

[Minter]

How do you pressure test the valves? I have had good success leak testing valves by pouring petrol into the ports (one at a time) and seeing if it leaks into the chamber, but it sounds like you are actually pressurising the chamber somehow.

All i simply do once the valves have been reground with course and fine paste is to squirt some penetrating oil around the valve and then with an air line blow air into the inlet and exhaust port whilst hold down the relevent valve with my thumb - no bubbles happy days - bubbles bit more grinding.. I also check the same way once the valve springs are fitted too.

[jungleMTbiker]

Yes, I also do the preliminary testing with with just thumb pressure, no springs, then test again after I've installed the springs.

[Minter]

Fired it up on the test rig! I was only priming it and it leapt into life!

Here's some more pics, just need to fit in the bike now.....



Cylinder head at the start!...



Should be able to fill that hole now!!



The jigsaw!

Pic taken just after she was purring like a kitten!

[Minter]

Been a busy productive night! Here's Chris's 500 purring away back where it belongs.. Mikuni now rejetted and ultrasoniced and a remote cable operated choke fitted...

Just a few 'a' jobs to do before the MOT on Saturday..

[Minter]

All ready for its MOT tomorrow and then the fitting of some nice new T63's ready for N Wales!



Inside of tank in a pretty bad way - could do with lining - just dont use reserve for a bit and clean out tank again before you do use reserve!



Jigsaw now complete.. starts and runs like a new un!

[MadStu]

Nice! You're like some kind of wizard