Engine buggered - a sort of rebuild thread...

[Bunker]

Blagged a 560 barrel and piston off Mr Kay, all perfect fit (even pin to head height, so stroke is ok) to replace my buggered barrel etc. Been offered a couple of 604 heads so contemplating that. Whilst at it, cleaned out the piston detritus from the filter, checked big end, ok. Took clutch apart while at it, surprised to find 9 friction plates with 1mm steels (rather than mil-spec 8 plates and 1.25 steels, I seem to recall civi spec is 7 friction plates!) and perforated clutch basket - a good mod to allow the oil to pass through easier.
Stripped old head of useful parts including my 670 cam.

Gave up when faced with reseating the starter motor cover seal - a right dog of a job...

A good evenings work.

(Mr Kay stripped his old head down and the replacement head so can start to rebuild his smokey old lump..)

[Bunker]

Ok, got meself a replacement 604 heed and managed to blag a 560 barrel and piston off Mr Kay (thanks mate). So actually, this will result in a bigger engine - huzzah!

[digger]

Simon, does that mean I can keep the engine thats gathering dust in my garage

[Bunker]

Simon, does that mean I can keep the engine thats gathering dust in my garage

no chance amigo...need that for the Unborn....

[Bunker]

Finally got the rebuilt lump back in the bike last night and finished the timing and cables off this evening. Slowly getting there, should hopefully get a road test in the week.......

[Bunker]

All connected up, problem with neutral sx but covered that in the Problems/Electrical area. Put the tank on, re-checked all connectors, hoses etc, put a litre of oil in the clutch case and one in the filler neck (only had 2 litres but thats enough to test with), kicked it over a few times to check then hit the orange button.............



bop bop bop bop bop


amazing, never seen the like....runs amazing except the smoke....Mein Gott the smoke, pouring out the pipe!! Hoping its just where I oiled the cylinder to put the piston in etc..

had to shut it off quick due to time, will revisit Saturday...

[MadStu]

Excellent Good news!

[Green Goblin]

[quote="Bunker", put a litre of oil in the clutch case and one in the filler neck (only had 2 litres but thats enough to test with)[/quote]

Ins't that what started this thread of, a lack of oil.

[frenchy3]

Excellent news. As for putting only two litres of oil in......its better than the one pint i made it back from france with.Putting two litres in the bike that method is still better than pouring three litres straight in and getting about two on the garage floor!

[Bunker]

It wont stop smoking and I had black oil dripping through the headers - mid section (!) of the ehxaust plus if I held a rag to the can, it went black and oily.....the pipes will have crap in them as the old head exhaust manifolds had oily detritus in them too. Been advised thats probably the piston rings.....triffic. Thatll be engine out and apart, again.

Thankfully Minter is on hand to come and give moral and skilled support later this week...now need to ask Mr Rotax the price of new rings......Im frightened!!.....should just stick a 350 back in and be done with it......