007, A Laverda 1200 Story

Discussion in 'Some Assembly Required' started by G 981, Dec 3, 2018.

  1. Wildebeest90210

    Wildebeest90210 Long timer Supporter

    Joined:
    May 24, 2013
    Oddometer:
    2,985
    Vapour blasting peens, does not remove any material and also prevents corrosion by effectively sealing the surface. I've got 5 year old vapour blasting on one of my bikes and it's as good as when it was done. Great finish for ally.
  2. G 981

    G 981 Been here awhile

    Joined:
    Sep 7, 2010
    Oddometer:
    735
    Location:
    West of Glaschu
    So, today I fitted the alternator cover and associated gubbins that live behind it.
    Starter clutch and idler gear, inner alternator cover with new bearing and oil seal.
    Just waiting for the special nut that tensions the starter clutch to the crank and bears against the oil seal.

    [​IMG]2019-07-01 10.37.33 by Grant Duguid, on Flickr

    [​IMG]2019-07-01 10.41.06 by Grant Duguid, on Flickr

    [​IMG]2019-07-01 10.48.32 by Grant Duguid, on Flickr

    [​IMG]2019-07-01 12.47.43 by Grant Duguid, on Flickr

    [​IMG]2019-07-01 10.51.36 by Grant Duguid, on Flickr
    Cogswell, AK650, JagLite and 4 others like this.
  3. G 981

    G 981 Been here awhile

    Joined:
    Sep 7, 2010
    Oddometer:
    735
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    West of Glaschu
    Some more bits and bobs arrived today. Fitted the front needle roller bearing and tensioner blade in the primary cover and bolted it all up.
    Also received the special sleeve nut for tensioning the starter clutch to the crank on the right hand side.
    And finally, the new low comp (as original spec) pistons arrived, along with gudgeon pins and circlips.
    I already sourced the rings separately.

    The cylinder block may arrive late this week, likely early next week and then I will have everything I need to complete the full restoration. Still a hell of a lot of work to do but it's plain sailing from here on in.

    [​IMG]2019-07-02 13.07.03 by Grant Duguid, on Flickr

    [​IMG]2019-07-02 13.18.46 by Grant Duguid, on Flickr

    [​IMG]2019-07-02 13.20.10 by Grant Duguid, on Flickr

    [​IMG]2019-07-02 13.22.05 by Grant Duguid, on Flickr

    [​IMG]2019-07-02 12.50.57 by Grant Duguid, on Flickr
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  4. YamRZ350

    YamRZ350 Been here awhile

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    Dumb question: why all the extra copper washers on the tensioner?
  5. G 981

    G 981 Been here awhile

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    Oddometer:
    735
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    Once the bolt is adjusted to take up the slack in the primary chain there is a certain length of the bolt sticking out from the lock nut. The end nut is domed so can't be screwed in too far before bottoming out.
    So the stack of copper washers can be increased or decreased to fill the gap between the domed nut and the lock nut.
    As the chain wears and stretches, and the adjuster is screwed further in, less copper washers are required.
    AK650, JagLite and chris a like this.
  6. G 981

    G 981 Been here awhile

    Joined:
    Sep 7, 2010
    Oddometer:
    735
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    Ok, jumping back and forth today.
    As I'm fitting GSXR wheels to the blue bike it needs an offset 520 chain to clear the 150/70 rear tyre.
    The offset front sprocket arrived and was duly fitted.

    [​IMG]2019-07-04 10.09.09 by Grant Duguid, on Flickr

    [​IMG]2019-07-04 13.52.05 by Grant Duguid, on Flickr

    Fitted the rings to the 80.00mm pistons for 007. Will now mount them to the conrods tomorrow.

    [​IMG]2019-07-04 10.32.44 by Grant Duguid, on Flickr

    [​IMG]2019-07-04 10.36.30 by Grant Duguid, on Flickr

    [​IMG]2019-07-04 10.47.11 by Grant Duguid, on Flickr

    And finally, lapped in the valves for 007's head. Should get the springs back in tomorrow too.

    [​IMG]2019-07-04 13.35.42 by Grant Duguid, on Flickr

    Cylinder block should be here early next week and then it's a matter of finishing off the motor build and finally fitting it in the frame.
    AK650, Rick4003, busa1300 and 3 others like this.
  7. Kai Ju

    Kai Ju Long timer Supporter

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    I have not seen one piece oilrings on anything other than an Airhead. Who makes the pistons ? Mahle ?
  8. G 981

    G 981 Been here awhile

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    Oddometer:
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    The oil rings have 3 parts, external ring, spring inside and pin to hold the 2 ends of the spring together.
    Asso made the original pistons, and I think these are originals.
    AK650 likes this.
  9. Kai Ju

    Kai Ju Long timer Supporter

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    Thanks for the clarification, I was comparing to conventional three piece rings which have the expander ring and two thin rails.
    Airhead one piece rings are just that, one piece. Easily broken and razor sharp on the ends when you spread them to install them on the piston.
  10. G 981

    G 981 Been here awhile

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    I have seen that type of oil control ring on aftermarket high comps.
  11. MZRider

    MZRider Neo-Luddite

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    Moto Guzzi pistons (made by Mondial, Asso, Gilardoni) use one-piece oil control rings. The V700 used two!

    [​IMG]
    JagLite likes this.
  12. G 981

    G 981 Been here awhile

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    Must be a wide valve angle on those heads...

    Here's some Laverda 1200 9.8:1s on the left vs 8:1s.

    [​IMG]P8152065 by Grant Duguid, on Flickr
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  13. Crisis management

    Crisis management Latte riders FTW!

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    In the late 1970s I worked for Repco manufacturing here in New Zealand (manufacturer of OEM and aftermarket pistons, liners, rings and valves), the one piece oil control ring was very common, about 50% of production IIRC, made from spheroidal graphite cast iron and a bastard to fit without losing blood. Thinking back I recall a lot of that style of ring on diesel pistons but I maybe hallucinating.
    AK650 and Kai Ju like this.
  14. nickguzzi

    nickguzzi Long timer

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    They were so common at one time SnapOn made a ring fitting tool to preserve our finger tips. Worked on other rings too.

    [​IMG]
    SnapOn ones are priced accordingly, cheap copies about £7.
    chris a likes this.
  15. G 981

    G 981 Been here awhile

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    Oddometer:
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    I had no problem fitting the rings by hand.
    Well, today the cylinder block arrived back fresh from boring out the mouths and fitting larger liners as it was taken out from 1000cc to 1200cc.
    The original liners were toast after a rod let go, and were not able to be saved as 1000cc, so only way to re-use them was to take them out to 1200cc (actually 1116cc to be accurate, vs 981cc before).

    Before:

    [​IMG]2019-01-27 09.33.02 by Grant Duguid, on Flickr

    After:

    [​IMG]IMG_20190705_083519 by Grant Duguid, on Flickr
  16. G 981

    G 981 Been here awhile

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  17. G 981

    G 981 Been here awhile

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    Waiting for new billet cam bearings to arrive before I can button up the engine.
    Fitted the 530 drive sprocket today, every little helps.
    Next week I will lift the engine into the frame and then it will all start to come together nicely.

    [​IMG]2019-07-12 09.48.37 by Grant Duguid, on Flickr
  18. G 981

    G 981 Been here awhile

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    So, while waiting I started on another 1200 engine. This one had been in a hell of a state when it arrived.

    [​IMG]2019-03-07 12.11.36 by Grant Duguid, on Flickr

    [​IMG]2019-03-07 12.11.59 by Grant Duguid, on Flickr

    [​IMG]2019-03-19 10.57.42 by Grant Duguid, on Flickr

    [​IMG]2019-03-19 12.49.20 by Grant Duguid, on Flickr

    [​IMG]2019-03-20 11.28.52 by Grant Duguid, on Flickr

    [​IMG]2019-03-20 11.28.33 by Grant Duguid, on Flickr

    Should get it finished before the end of the month.
    Replacement crank, gearbox, clutch.
    New high output oil pump.
    Rebuilt crank, rebored cylinders with new high comp pistons, rebuilt head.
    All cases vapour blasted.

    [​IMG]2019-07-10 14.35.21 by Grant Duguid, on Flickr

    [​IMG]2019-07-11 09.34.46 by Grant Duguid, on Flickr

    [​IMG]2019-07-11 10.12.05 by Grant Duguid, on Flickr

    [​IMG]2019-07-11 12.51.10 by Grant Duguid, on Flickr

    [​IMG]2019-07-11 13.16.33 by Grant Duguid, on Flickr

    [​IMG]2019-07-12 09.20.09 by Grant Duguid, on Flickr

    [​IMG]2019-07-12 13.07.03 by Grant Duguid, on Flickr

    [​IMG]2019-07-13 09.32.18 by Grant Duguid, on Flickr

    [​IMG]2019-07-13 09.46.32 by Grant Duguid, on Flickr

    [​IMG]2019-07-13 10.29.55 by Grant Duguid, on Flickr

    And side by side with 007's engine, both needing minor work for completion.

    [​IMG]2019-07-13 11.57.58 by Grant Duguid, on Flickr
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  19. Chickenstrip

    Chickenstrip Long timer

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    The pics are showing evolution from rusty mess to revitalized beauty? Wow! How did you deal with the rust on the tranny gears? Was it just a matter of wiping down, or was there pitting that required removal/healing, replacing?
  20. G 981

    G 981 Been here awhile

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    Hell no. As I said above I used replacement crank, gearbox and clutch assemblies.
    The originals were just too far gone for economical repair.
    As supplies dry up, who knows, maybe one day they will be reused.

    I was surprised just how well the crankcases came up after vapour blasting. I thought initially they also might need to be replaced.