Motor strip

[tlmark]

Oh yeah, the barrels have come back from SRM with new pistons and I had the barrels stove enamelled as they were powder coated...  
There have been lots of odd things done to this bike.

[berger]

very nice and you've got one of the most proud barrel gasket faces ive ever seen .what make are the pistons?

[tlmark]

The Pistons are 8.75:1 GPM +40"  is that good I don't know that's just what they sent.

[tlmark]

Took the bottom end into work do the next stage of the rebuild.
thought I'd check the end float with as it came apart (less the missing shims )    blimey       0.68mm or .027"

[tlmark]

That, of course, includes the damage to the web where the small boss has been worn away!

The Crank just bearly fits on to our little lathes at work, so running a dial gauge on it at the moment.

a couple of things now everything is washed and in good light (not the garage) the new SRM timing side bearing is longer than that installed at the moment?
and it looks like the camshaft bearing on the drive side is quite worn so I'm going to need to get that out.

[tlmark]

So the drive side camshaft bush was refusing to come out even with a blind bearing puller! Never seen one of these before what a great bit of kit. I borrowed it.

The only thing we could think of was to cut the bush out by milling it away and then using the puller. and this worked a treat. And now looking at the old bearing most of the oil scroll has worn away! So I wouldn't mind betting that bush has never been changed. and most likely the cause of the wear to the cam in the first place
So now we move on to removing all the other bearing/bushes. 

think I'll use that nice puller again 

[coater87]

Those are really nice tools.

 First time I used one I gave myself a blood blister the size of Australia 

Lee

[chaterlea25]

Hi Mark,
Heating the cases up (evenly) will make removing the bushes easier,
It will also make fitting the new bushes a piece of cake, correct temp is a sizzling spit   
The cam bushes will need line reaming once fitted

I have a couple of different sizes of those pullers and they are the biz when you need them

John

[tlmark]

Cheers guys 
all bushes are out not had much time on it today but I have deburred all the new bushes oil scroll ways as they were quite burred and probably wouldn't have passed much oil. 

[tlmark]

On another note does anyone know the clearance between the main bearing bush and crank? I did look but can't find it anywhere.   

[coater87]

 after the bushing is installed and line bored, .0015 thousandths is a very good target.

 And the old adage applies with engines, a little too loose is much better than a little too tight.

 Lee

[tlmark]

A little more progress made now the snow has gone.

A new shaft fitted to the idle gear, man that was tight to get in 

And I have managed to get the end caps off of the sludge trap. The drive side was tricky as the slot had been chewed before I started but a colleague suggested using a centre punch in the corners of the slot to get it moving! and this worked a treat a good tip if you're ever in the same situation.
On inspection, it was lovely clean inside    I have already bought a new trap and end plugs so those a ready to go in next.

[chaterlea25]

Hi Mark.
The tube needs o be removed as  the sludge gathers between it and the flywheel before it starts to fill the tube itself

John

[Greybeard]

My Plungy did not have that tube. I don't know when it was introduced.

[tlmark]

Hi Mark.
The tube needs o be removed as  the sludge gathers between it and the flywheel before it starts to fill the tube itself

John

Cheers John

I would have taken it today, I bought my Whitworth sockets in to take the flywheel bolt out only to find its not a Whitworth 

so may mixed types of nut and bolt