Intake Pistons Barrels

Started on the top end, fitted reeds and intake rubbers, fitted the pistons and barrels.

Clutch Parts

 Cleaned up the Clutch push mechanism over the weekend, the layer of grease and dirt has had a surprisingly insulating effect on the parts, minimal rust and corrosion.

When I bought the engine many moons ago the clutch cable holder on the left side of the crankcase was missing, these are not available to buy as a spare part, there are a few sellers on ebay looking for €30 + postage, I decided to make one up from a cutoff of 25mm diameter aluminium rod. Works great!

Engine Back In

 With the engine out and neutral position in the gearbox resolved I cleaned the cases again and applied fresh gasket cement. The engine was buttoned up, the stator reassembled after some modifications and fitted.

The modifications i followed were listed on the 2strokeworld forum, here is the thread http://www.2strokeworld.net/forum/index.php?topic=855.0

I mods included removing part of the crankcase to help the base plate sit flush. Fitting 2 extra countersunk screws to two plates where there was initially 2 screws and applying some gasket cement to prevent a possible shorting event from wires vibrating against the housing.

With the engine in the frame I started assembling the wet side of the engine, Kickstart and gear change mechanism fitted. I had to fit 2 new screws/bolts to one of the retaining collars, 7 years ago when I disassembled the engine the original screws had to be forceably removed. I used stainless bolts with blue thread lock.

I am a bit confused [again] I see to be missing some sort of retaining collar from the clutch shaft, there are 3 screw holes, 2 can be seen to the left of the shaft. I cannot see this part on any schematics, does anyone know what It is and where to get one?

 

So moving on I decided to prep the clutch basket, I filed down the groves on the basket and give all the parts a good clean in some fresh petrol, next up is the clutch build.

 

 

 

 

Neutral Test on the Bench

Cases cracked open, and the selector drum is correct, a lot of head scratching done....

Back on the Bench

Engine back on the bench until I figure out what is going on with the gearbox, after cleaning up the messy bench.

Powerdynamo

New electronic ignition has been fitted today along with brackets to hold the new coil and rectifier. Some 4mm offcut plate and scrap aluminium was used.

Joey Dunlop

Engine in

Got the crankcases sealed with 3 Bond 1215 and buttoned up last night. Tonight was engine in frame time, what a battle! I certainly didnt make it easy for myself with my positioning of the mounts but its in but not tightened up.

Bottom End

In order to plan for the electric connection of the ignition system I have been building the bottom end to fit the "powerdynamo" ignition.

Electrics again

Spent a good few hours over the weekend fiquring out colours and connections. I abandonned ship until I get the engine bottom end fitted. I will be running a powerdynamo setup for ignition.

Rear Brake

A lot of work done over the last few days, rear braided brake line made, fitted and brake bled.