Timing and Heads

Finished the ignition system today by setting the timing and fitting the flywheel followed by fitting and torquing the heads.

The gap betwen the pickup and the ramp on the flywheel is 0.016 and the timing set to 1.89mm BTDC.

The heads were fitted and the newely coated red head bolts torqued to 19nm.

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.

 

 

 

 

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.