Right I have decided that the time has come to try and finally sort Kurgan out.
After all its not thru lack of parts (well hopefully not).
But to be honest its been some 8 years since i have stripped an engine down then only old Honda 500/550 Four SOHC's. Never a twin cam before, so here goes.
Todays plan is to strip Kurgans old engine down of its top end, and see what condition the bores, pistons & rings are in.
Once I have done this I will be doing the same to the donor engine ( that I hoped was a good engine). and between the 2 I am hoping to be able to rebuild the top end.
I do have a 3rd Cylinder block with pistons but no rings that has about 10000 miles onit.
AS for a time scale for all this work, we will see. I should know more later today.
1st job is to get Kurgan's old engine into some clear space, so I can spread out the parts as I remove them
I had already removed the breather cover to get the engine out of the frame.
So I tear away the old Gasket and remove the 2 cross head screws (not sure if I needed too).
There are 2 pieces of gauze underneath the old gasket, I presume they are meant to be there, altho they look a bit like chicken wire !
Off Come the left end caps & spark plugs
Off Come the right end caps & spark plugs
Then its time to loosen all the alLAn bolts from thE rocker cover
and remove - have put on the floor with all the allAn bolts in there original locations.
Here's thE bit I'm not looking forward too, altho not looking forward to putting it all back together again even more....
Moz Morris - dont forget to hold them cams down with mole grips before undoing the carriers...saves stripping the bolts....tell me to shutup if ya like lol
Am presuming I am doing right buy making sure Ive got TDC on no 1 cylinder. ( well its the way i used to do it on the old Honda's so fingers crossed).
Next job is the cam chain auto adjuster - time to have a good look around it.
Took me a while before I found the adjuster screw, so loosened of the locking nut and screwed the adj screw inwards
I have removed the bolts and it comes free - no nasty noises when I removed the unit so must have done it right.
took me a while to see how this plastic cam chain guide comes out !
it Just lifts free
Now its time to start to remove the cam shafts,
I slowly and as evenly as I can remove all the bolts on the 4 cam shaft holders
and carefully lift them off
Then I remove the cam shafts and carefully put them on top of the cam shaft holders.
Just in time remembered to put a screw driver to stop the cam chain falling down into the bottom half of the engine.
I remove the 2 screws at either side of the cylinder head.
and the one at the middle front of the cylinder block.
I then start on the 10 Cylinder head bolts, this turns out not to be quiet straight forward,
with 2 studs coming out with there nuts.
The I find this a 17mm nut were a 14mm nut should be !
Shit another one - and the sockets wont fit as there's no room between the nut and the cylinder head,
after taking some 30 odd mins hunting around in another shed I find a 17mm Box spanner, which with a bit of persuasion with a hammer does the trick
A gentile tap with a small clock of wood and a hammer slowly has the Cylinder head free and ready to be removed.
The bloody battery has gone flat on the camera, so its time to have a nice cool drink of juice, Some lunch and get it on charge.
Whilst waiting I decide to upload the pics of today's effort so far.
I will be back in the shed in about an hour when the battery has charged up.
The camera batteries are charged up ive had lunch, so lets crack on.
Off comes the Cylinder head and is carefully placed with the rest of the top end taken from Kurgans old engine.
Tho top of the pistons don't look bad and from what I can see the bores dont look to bad either.
I Notice the broken oil way ring at bottom left ?
this was probably the cause of the slight seepage I had on this side of the engine
off comes the barrels - nice n easy as well.
from left cyl 1 & 2
None of the next 4 pics have i cleaned the bores yet.
Cyl 3 & 4
At the moment they look in very good order inc cyl 2 which was down on pressure compared to the other 3 !
I will clean them up then mike them when I can find the Suzuki Measurements.
all the rings seem free inc the oil rings - but wont know until I remove them and mike them up - when I can find the Suzuki measurements.
Providing all the pistons are the same size got 8 pistons and sets of rings to make up the best set.
If this fails then the engines are scarp as STD piston rings are no longer available & I am
not prepared to spent more money on this bike ( not that I have any to spare)
Stephen Osborn - They may well do Doug, but as you know my Finances are not close to being healthy!
all looks good so far
Doug Ashburn - the rings are shot on that ....see the brown blow past on the rings
Stephen Osborn - no m8 I hadn't :( :(
Doug Ashburn - i can see and its hard from pics
Stephen Osborn - will take some more next time i am in the shed and i wont reduce them
I have stuffed paper towels to stop muck getting into the bottom end.
Once I have finished and Kurgan's running or I finally give up this will end up on ebay for much need funds for the CBR1000 project.
Didn't think I would get this far today.
and I don't feel to bad,
altho my sight is blurring but I decide to carry on for a bit more.
Off goes the throttle cables
Off comes the Petrol Tank
ready to carry on.
but now going really slow as my eyesight is blurring really bad now
Off comes teh coils
off comes the carbs.
these will find there way on ebay on next free listing day as I plan to use Kurgan's Cylinder head & carbs
off comes the breather and pipe
Loosen the Rocker cover bolts and remove the spark plugs..
I Loosen the Rocker cover bolts and remove the spark plugs
off comes the rocker cover
looks nice n clean inside
Off comes the Auto cam Chain Tensioner
Removed the exhaust pipe mount bolt
Off comes the Tacho cable
Now my eye sights too bad I cant see the bolts anymore so decide its time to have a rest n take me meds.
Hopefully will have a few hours tomorrow if not will be Wednesday
But all in all not a bad day I think
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