You’re doing a lovely thorough job on that 
Latest Project
- Thread starter nicholsonj2252
- Start date
New rear main seal in and a new flywheel o-ring then re-fitted the flywheel with new bolts
New oil pump O ring fitted and then onto the clutch again with new bolts and washers
A bit Staburags NBU 30 PTM on the mating edges and all went back in no problem
New stainless pushrod tubes fitted
Barrels , pistons , heads fitted
Valve clearances set and end float checked
Final gearbox seal that needed fitting (clutch pushrod) put up a fight . The bearing/seal puller couldn't grip it so some gentle persuasion with a small punch to deform it inwards and it came out with no marks whatsoever to the gearbox housing and the new one went in no issues with the seal driver
Rocker covers fitted , spark plugs in and bungs in the inlet and exhaust ports to keep debris out
Sump re-fitted with new gasket and oil filter in
Starter motor re-fitted
Filled with oil and turned over by hand and all nice and smooth
Away with work from tomorrow so there will be no more progress until next weekend
I'll order the parts I need so they are at home when I get back
New oil pump O ring fitted and then onto the clutch again with new bolts and washers
A bit Staburags NBU 30 PTM on the mating edges and all went back in no problem
New stainless pushrod tubes fitted
Barrels , pistons , heads fitted
Valve clearances set and end float checked
Final gearbox seal that needed fitting (clutch pushrod) put up a fight . The bearing/seal puller couldn't grip it so some gentle persuasion with a small punch to deform it inwards and it came out with no marks whatsoever to the gearbox housing and the new one went in no issues with the seal driver
Rocker covers fitted , spark plugs in and bungs in the inlet and exhaust ports to keep debris out
Sump re-fitted with new gasket and oil filter in
Starter motor re-fitted
Filled with oil and turned over by hand and all nice and smooth
Away with work from tomorrow so there will be no more progress until next weekend
I'll order the parts I need so they are at home when I get back
As I wasn't leaving to travel to work until later this afternoon decided that before I got too far into the re-assembly I would check that the engine was cranking over OK , which it is but the starter motor had a noticeable "run on squeal"
Removed it to investigate and sure enough the problem is the pinion splines - they have clearly overheated and have burrs on them
Looking at it I don't think I can just "dress" the burrs on the splines . The internal splines in the pinion are all OK
So looks like a new starter motor is needed unless I can just get a pinion
Removed it to investigate and sure enough the problem is the pinion splines - they have clearly overheated and have burrs on them
Looking at it I don't think I can just "dress" the burrs on the splines . The internal splines in the pinion are all OK
So looks like a new starter motor is needed unless I can just get a pinion
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One simply must admire your skill and perseverance - not to mention your uncanny ability to find spare parts!!!
Hope you find your pinion
Hope you find your pinion
Excellent, another ‘must watch’ endeavour.
Thanks for sharing your top notch work.
Thanks for sharing your top notch work.
Quite agree.Excellent, another ‘must watch’ endeavour.
Thanks for sharing your top notch work.
Thanks to Tim a used replacement pinion shaft is on its way so hopefully a fix is on the cards 
I’ll update one I’ve received it and got it stripped down and installed in my starter
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I’ll update one I’ve received it and got it stripped down and installed in my starter
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Agreed,there are some top engineers on here
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Replacement starter shaft received and it looks great , I’ll get it re-assembled tomorrow and hopefully report back that I’ve got a fully working starter motor
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Will this bike be a keeper John, or will it become available to purchase ?
Replacement starter shaft received and it looks great , I’ll get it re-assembled tomorrow and hopefully report back that I’ve got a fully working starter motor
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Can you slow down a bit please fella.
You’re showing us up with the pace of this rebuild
I am trying to pace myself as it was supposed to be a 3 month project but once I get going I find it difficult to stop LOLCan you slow down a bit please fella.
You’re showing us up with the pace of this rebuild
On that note I've just come in from the garage and I am happy to report the starter motor is now back together working as it should and re-installed on the bike
Managed a couple of hours in the garage this afternoon , got the clutch actuator arm re-installed with a new boot and jubilee clip
Addressed a few small surface rust patches on the frame with Kurust and smooth black Hammerite
Put the airbox back on along with the starter motor cover
Removed the front wheel and forks and checked over the steering head bearings , all was fine with just very slight marking on the bearing outer shells and will just need cleaning and packing with fresh grease
Stripped the forks down to address the leaking fork seals , looks like the original seals and from the smell and colour of it the original oil
I'll get the fork seals fitted and the front end back together in the morning hopefully
Addressed a few small surface rust patches on the frame with Kurust and smooth black Hammerite
Put the airbox back on along with the starter motor cover
Removed the front wheel and forks and checked over the steering head bearings , all was fine with just very slight marking on the bearing outer shells and will just need cleaning and packing with fresh grease
Stripped the forks down to address the leaking fork seals , looks like the original seals and from the smell and colour of it the original oil
I'll get the fork seals fitted and the front end back together in the morning hopefully
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Didn’t have any bricks lol
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Eeee John Lad!!! There was NOW'T gentle about that
once could even go as far as to say
"It were reet, Violent!!"
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