Insert clever airhead based title here ....

Discussion in 'Airheads' started by planktonnn, Aug 25, 2009.

?

I have been to the county of Fuckshire, it was ...

  1. Nice?

    33 vote(s)
    13.6%
  2. Nasty?

    36 vote(s)
    14.9%
  3. Nasty but nice?

    174 vote(s)
    71.9%
Multiple votes are allowed.
  1. Stagehand

    Stagehand Imperfectionist

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    I'm sure the engine not spinning well couldnt have anything to do with the ferrous cornflakes in the sump either? :ear
    #21
  2. planktonnn

    planktonnn .also, i am a twat

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    Ah, hang on, crossed wires. The cornflake sump is from my other boxer. We've not taken the sump off The Standard One yet. It's raining :D
    #22
  3. Stagehand

    Stagehand Imperfectionist

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    oops! my mistake. Carry on!
    #23
  4. bpeckm

    bpeckm Grin!

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    I was going to suggest that a swollen clutch might be dragging and asking you to turn some gearjuice, until I saw the photo......

    Next-most-likely suspect is going to be rings/jugs.... not likely to be bearings, eh? A quick pull of the heads will tell you pretty quickly, without having to pull the sump. An '85 will have the Nikasil jugs, which are pretty tough and unless major pitting is an issue, likely be fine. Lots of folks pop in new rings without work to the jugs, but you will want to read up on the vagaries of the Nikasils for your own comfort/edification......

    :D
    #24
  5. Stagehand

    Stagehand Imperfectionist

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    Presumably with these guys a bastard file will take care of any cylinder rust. :lol3
    #25
  6. planktonnn

    planktonnn .also, i am a twat

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    Surely a bastard file would be too fine for our purposes, I was thinking TNT a la mythbusters & the clogged up cement lorry? :D
    #26
  7. planktonnn

    planktonnn .also, i am a twat

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    The clutch certainly was dragging, because with the gearbox on, bike in gear and the clutch lever arm wedged full forward to disengage the plates*, you still couldn't turn the back wheel. The starter was off so we could see the plates moving, apparently fully separating, but we still couldn't turn the wheel beyond the take up in the driveshaft shock. Once off the gearbox turned smoothly from both input & output ends, so that's fine as far as we can tell at this stage in the process** We could lever the crank round on the teeth of the starter drive ring, though there was some debate about the length of lever my co-constructor was allowed access to as I have heard the sound 'snap' on far too many occasions to welcome it into my ear again. He was gentle though, as gentle as a horny giraffe on a rocking horse, and it shifted round but there's still a tightness. I've plooked penetrating free-all magic fluid into the cylinders and we'll see how it progresses***

    I'm sort of leaning toward bound rings, but the barrels will have to come off as part of getting to any bearings anyway, and if we discover the problem at that stage, and can flap*** the big ends & rotate the crank, then we know we're ok. If the crank doesn't rotate it could still be something locking in the cam line?, but if we disassemble in the right order the problem will become apparent through the elimination of what isn't broken. Probably :D

    My other boxer ('DMW') is a '78 block with post '81 nikasil barrels****, in a '79 chassis with a K100 front end. I'm thinking the nikasils on this new one will be ok, but all will become clear when we get the barrels off. I don't know what I'm doing as I failed metalwork, but I'm trying to follow a sequenced chain from 'most likely', thru 'if not, then it could be...', to 'ah, there it is' :D Or, as we say roun' these 'ere parts:

    We go toward by coming from.

    Tatty Bye.

    * A shortage of nipples was to blame. Apparently not a problem Lily Allen has to face?
    **Process? Hahahaha!?!
    *** A technical term used in the measurement of 'Not Stuck'
    **** Don't use the rubber rings on the skirt or it won't fit down, the pre '78 crankcase mouths are very slightly smaller? I found the rubber ring just sheared and the base of the barrel leaked.
    #27
  8. bpeckm

    bpeckm Grin!

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    Cam chain is certainly in the "after we pull the jugs" category, I would even say after you pull the pan. Cam chain is pretty straightforward with a tensioner, two gears and an endless chain... not likely to be the source of any particular friction...valve train again not likely to be a big problem, but pulling the heads and jugs will tell you more in that department.....

    Another thought: take a look inside the front cover and see if perhaps the alternator rotor has "swollen" to the point that it binds with the armature.... again, not real likely, but very easily dealt with. Make sure you have the proper hardened rotor-puller bolt, and then the rotor pops off (should?) easily....

    :D
    #28
  9. Dirtyboydeadly

    Dirtyboydeadly AKA. Shineyboydudley

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    U want to keep ur corn flakes in the packet, not ur sump silly :evil
    [​IMG]
    #29
  10. planktonnn

    planktonnn .also, i am a twat

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    I am walking toward your frame with a hacksaw and hammer... :evil:evil
    #30
  11. Dirtyboydeadly

    Dirtyboydeadly AKA. Shineyboydudley

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    Right i'm coming over and i'm bringing back up ( the wife ) :rofl
    #31
  12. planktonnn

    planktonnn .also, i am a twat

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    I'm still waiting :rofl
    #32
  13. planktonnn

    planktonnn .also, i am a twat

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    Thanks, I'll take a good look thru those with a large coffee :thumb
    #33
  14. planktonnn

    planktonnn .also, i am a twat

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    This afternoon we took the barrels off the new one, and as we hoped the crank turns v freely now. The r/hand piston had, as suspected, bound into the barrel after 4 years sitting in a salt bog*, and in the end the simplest way to free it was to remove the studs & twist the barrel until it became free and could be pulled off. A couple of sections of the nikasil plating had already come away, independent of the piston stickage, so the barrel is in the 'pretty useless for now' store (my shed). It looks like the bike will go back to the 800 it was born as, because we have a paired set of 800 populated heads/nikasil barrels/pistons/carbs etc. in the spares department (my shed) which need checking but should be ok, and will accept the stainless downpipes we already have.

    This is called 'Having a great pile of spare shit that may someday come in useful'.

    Next, it seems the clutch/flywheel need pulling off & the rear crank oil seal needs checking, as it all looks a bit 'oily in the bellhouse' if you know what I mean. It may be fine but I think we've agreed it's better to check it while we can get at it. The clutch assembly & flywheel will need to be marked to retain their balanced state, if indeed they are balanced. The subframe & pannier racks are off being stripped & painted, and once the engine is out of the frame then it and the frame can be scrubbed up too. Then we can start sorting the electrics & reassembling it all. That all sounds a little too simple doesn't it?

    Overall it's moving at a good pace, with no major problems so far. I would have liked to have got on with the fairing repairs today, but I was slightly tied up with the other boxer and its disintegrating big end shells, which I'll tell you about later.

    Goodnight Corporal.


    * It might as well have been.

    PS. I have broken my Brane
    #34
  15. bpeckm

    bpeckm Grin!

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    Fixed.


    btw, do look into the (o-ring) seal on the oil pump whilst you are behind the flywheel...easy fix, cheap, and the actual source of a lot of "main seal oil leaks"


    :thumb
    #35
  16. planktonnn

    planktonnn .also, i am a twat

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    Will do, cheers :thumb
    #36
  17. planktonnn

    planktonnn .also, i am a twat

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    When struggling with stuck things, or other things that piss me off, I think of this picture to give me a little cheer. Maybe it'll do the same for you?

    Attached Files:

    #37
  18. planktonnn

    planktonnn .also, i am a twat

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    So, the problem with the other boxer. At this point my camera has just landed in Washington DC, so pics are not possible, but oh - what a mess. :rofl

    The left 'jug' all came off easily enough, but the conrod was tight on the big end. Not stuck, but would stand on its own, which as it turns out, is a really good way of avoiding that whole 'conrod/crankcase mouth bang/dent' thing. The right jug was reluctant to come off, so I detached the head & found the piston was happy enough to move in the bore, so it was stuck somewhere else. Cue levering & prodding. Stopping, trying again. Repeat. Repeat again harder. I removed the studs, to get a bit more movement but it still wouldn't shift. Eventually it came off, though on the way it destroyed any reputation I ever had for ‘gentle’ :D

    <!--[if !supportEmptyParas]--> <o:p></o:p><!--[endif]-->
    Now bearing in mind that this bike (below) is a ’78 block with post ’81 barrels, it seems as if the back end of the bevelled edge on the crankcase mouth lip has very slightly folded into the empty o-ring groove on the piston skirts, and was discouraging the barrel from coming out past the groove. That, in case you wondered, is not groovy. I never could get the set-up to seal successfully while using the o rings, and was eventually let into the secret after 3 weeks of trying, and it has sealed brilliantly without o rings for the last 3.5k miles. Getting it out however was another thing, and it’ll need some work before the cylinder goes back in. But I have to deal with the wider problem before it’s time for that.


    The left conrod was as described, but the right had play. Plenty of play, about a shells depth of play I'd say. I would have had a look at the crank journals straight away, but as is the way with these things the universe and whatever forces operate therein decided to fuck with me, and then fuck with me some more. I hate those torx heads, and certainly the set of bits I have are utterly useless when it comes to the conrod bolts, or K75 head bolts, or anything. But then Dratty-boy-dudely arrived, took his ’77 airhead frame away so I couldn’t vent my anger on it, and returned with actual tools that work!?! And lo the bolts they did shift-eth unto release, and there was much rejoicing amongst the tribe of Bm W, though all were in bed by 10.30 and did not argue with their Nanny, oh no.

    You see, stopping, it’s the right thing to do. I could have not stopped. But I had to. All the other times I didn’t I right royally borked it up big stylee. So, at that moment just pre-damage you should stop. I do. I will now in fact.

    Pt 2 – ‘The horror, the horror’ coming soon to a thread near you. :p:p

    Attached Files:

    #38
  19. Jasper ST4

    Jasper ST4 Guest

    I can't wait for part two of the act. Right now I have visions of Egor standing over his Frankenbike saying "It's alive...ALIVE!!!"
    #39
  20. planktonnn

    planktonnn .also, i am a twat

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    Ah, well, I wouldn't be calling the undertakers quite yet, but you're right, it is all a bit 'rampaging villagers with pitchforks & flaming torches' around our way :jump
    #40