Berlina

Discussion in 'New Zealand' started by Padmei, May 27, 2012.

  1. Padmei

    Padmei enamoured

    Joined:
    Mar 12, 2008
    Oddometer:
    4,099
    Location:
    Nelson New Zealand
    Finally received the forks & front wheel back from the straighteners. Got all inspired & degreased & washed them.
    Looks like I have all the bits for a bike pretty much:clap

    I have the block on the bench & I think I was about to put the barrels back on with new pushrod rubbers. It's funny getting back into the engine rebuilding headspace after having a break for so long.

    I am now scouring thru the inspirational threads to get some ideas about what to change. I would like to fire the motor up first & make sure it is gonna work before I spend anymore money & a lot of time modifying bits & pieces for what may end up being a parts bike.

    This bike really turns me on - especially the seat. I've always wanted to make a wooden longboard so the seat really attracted me.
    [​IMG]


    http://www.pipeburn.com/home/2013/6/14/royal-enfield-bullet-500-hazan-motorworks.html

    Like this too

    [​IMG]



    Note to self. Please don't build anything that is as ugly as this

    [​IMG]
  2. Padmei

    Padmei enamoured

    Joined:
    Mar 12, 2008
    Oddometer:
    4,099
    Location:
    Nelson New Zealand
    My sump is a little like the lucky dip we used to have at the St Martins church fair (that was the St martins church that is now under the tar seal of a motorway in Mt Roskill)

    Anyway I stuck my hand into the boys bin & instead of pulling out a cool green paratrooper that you throw off the sundeck & watch it float down to earth, I got a pin, a white bung & either a spring or leftovers from the original stud repair.

    [​IMG]


    Now apparently that 10mm pin is an expensive piece of engingeering if it's not in its original location.

    http://ukgser.com/forums/showthread.php?t=341201

    As for the white bung - I'll take any suggestions. Choccy fish for the best one.

    Hmmmm.
  3. Night Falcon

    Night Falcon TRIUMPH TIGER 800XC

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    I'm picken that bung was left behind by oil thevin aliens :dic









    .....I like the normal chocy fish too - not those flash peppermint ones :puke1
  4. Micawberism

    Micawberism Been here awhile

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    1335591 is the casting number that the plug has come from
    It appears to be a relief valve, explains the spring also :puke1
    Check out the pic on post 5 on the site you linked :deal.
    Righto I will go stand by the letterbox and wait for my prize to arrive :D
  5. Padmei

    Padmei enamoured

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    Oooooh I will have to consult with the judges on that one. It sounds quite plausible well done Micarberateurism What parts fiche are you looking at?

    http://www.maxbmwmotorcycles.com/fiche/DiagramsMain.aspx?vid=51897&rnd=04302013

    [​IMG]

    Is it part 13 on the above diagram?

    Have you or anyone taken one of these plugs out before?

    As the motor is pretty much in bits anyway it looks like I may only need to spring for the cheap missing parts & a gasket. Best if I take it apart to assess if there is any damage caused.


    If you're wrong Knight falcon gets the choccy fish.
  6. Voltaire

    Voltaire Titanium and Ceramic Hipster

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  7. Padmei

    Padmei enamoured

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    I should really be taking all the hints someone is sending me & just part this bloody bike out. Grrrr.

    Ok I thought about the engine & the potentially missing main bearing locating pin & possible damage caused by oil starvation that happens when the main bearing spins & cuts off the oil supply.

    So the engine may be rooted or it could quite possibly be fine for another 30K. Since it's out of the frame & opened up it's only fitting I should have a looksie to satisfy my curiousity. I figured it's only gonna cost me a couple of seals & gaskets if everything is within coooee - if not well I'll know it's not worth carrying on tarting it up with bodgily home made pieces of magic. it's all in the name of science.

    I removed the front cover & inserted the alternator bolt with a short piece of ali rod in front to ease the rotor out. Unfortunately the bolt began spinning & the rotor was not going anywhere. I couldn't screw the bolt in or out. Bugger.

    Finally 2 homemade puller arrangements later...

    [​IMG]




    I managed to unscrew the bolt out.

    [​IMG]

    I thought I may have better luck if I took the front timing case cover off & somehow lever the rotor out. Buuuuttttt the top two screws are frozen in place. Some whacks, crc & heat haven't helped. I have left them soaking for a while & will see what happens.


    So here the engine sits.

    [​IMG]

    [​IMG]

    [​IMG]


    And of course who was sitting on the wall laughing at all this??? Our old friend the salad fork

    [​IMG]


    Anyone have any better ideas how to get the rotor out? I would say the chances are pretty likely the rotor now is rooted with the stripped thread or do you reckon it may actually stay there if tapped back on on reassembly?

    Unsure what to do now. I may put a thread up on airheads
  8. Pete-NZ

    Pete-NZ Long timer

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    May 8, 2011
    Oddometer:
    1,047
    Question..............
    Is that cap screw in pic 1 not going into the end of the crank shaft ?
  9. NordieBoy

    NordieBoy Armature speller

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    The salad fork is spooning :rofl
  10. Padmei

    Padmei enamoured

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    Yes it's a funny setup. The inside of the rotor is threaded then there is a gap & the inside of the tapered bit on the end of the crankshaft is threaded as well. That cap screw threads thru the rotor then becomes free then threads into the crankshaft.
    To remove the rotor you use a special long cap screw that is threaded up by the head but is plain at the end. As you screw it into the thread on the rotor it pushes aginst the crankshaft & lifts the rotor away.
    i used the original & slid a length of rod in to take up the space. Unfortunately as I screwed it in the thread on the inside of the rotor stripped.

    I think the rotor is only threaded inside for removal of the rotor.

    It's funny what a break & some pancakes with banana & golden syrup will do. When I went back & looked back at the job I reasoned that the only thing holding rotor on was the tight fit against the taper. I had sprayed it with CRC before lunch so got a drift & gave the rotor a short hard tap wherein it spun & i could lift it off :clap

    One fastening capscrew on the timing cover case was frozen in so I drilled it a bit till it began to spin & lifted it out.

    I removed the camshaft left it there.
    i need to get a splined socket thing for the conrod bolts & a puller for the timing chain sprocket.

    The big thing I learnt to day was to stop, have a break & think around the problem. Also there's no such thing as too many tools.
  11. Box'a'bits

    Box'a'bits In need of repair

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    I may have experience with this also. :D :thumb

    I've screwed loads of things up after getting frustrated (especially when I feel time pressured). Better just to walk away, ponder it, & come back fresh.

    Good to hear things are progressing again.
  12. Night Falcon

    Night Falcon TRIUMPH TIGER 800XC

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    ....or spoons
  13. Mark_S

    Mark_S Fair Weather Faggot

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    Kapiti NZ
    thatÂ’s what he was referring to
  14. Micawberism

    Micawberism Been here awhile

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    Spoons schmoons, its cold outside by the letterbox. Wheres me fish :ear
  15. Padmei

    Padmei enamoured

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    Ask Bitsa how long he had to wait for his:rofl

    Maybe at the cape to cape ride
  16. Box'a'bits

    Box'a'bits In need of repair

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    :d ....Ah, but you came through in the end...
  17. Micawberism

    Micawberism Been here awhile

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    Right then, thats that :huh )Pack up me portable generator, pipe and slippers :1drink, and go back inside by the heater :D
  18. Padmei

    Padmei enamoured

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    I'm going to start putting the motor back together tomorrow. I initially took it apart after finding the main bearing locator pin in the sump. What can happen without this inserted is the main bearing can twist & block off the oil galleries which can lead to melt down.
    So the main bearing looked ok as did the crank etc. Over the period of time the engine sat in bits on the bench the task of reassembling it seemed to get more out of my comfort level. A short period of re accustoming myself with the parts reassured me it seemed pretty straightforward as long as I reverse the method of disassembly.

    Remember this isn't going to be a RTW bike & only the bare essentials are being replaced as I want it to be a runner. I am reusing many parts like the gudgeon pins, old valve seats etc. It may only see a few thousand Kms over the next few years, if that.

    I am unsure about the lining up the crank sprocket with the cam sprocket. I believe on Schmidt I marked prettty well where they lined up however on this motor I haven't. I have noticed the cam has a timing mark & the woodruff key on the crank looks to be half way between TDC between both cylinders.I will check snowbums site but any help is appreciated.

    Also if there are any tips re anything to do with the motor reassembly.
  19. Box'a'bits

    Box'a'bits In need of repair

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    Crank & cam sprocket both have marks on them. Line them up at 6.00 & 12.00 o'clock when the engine is at TDC. Easy peasy.

    [​IMG]
  20. Padmei

    Padmei enamoured

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    No I can't see crank marks. Maybe I'll get the old one off Schmidt & check it out, the key would b in the same possy.