500 Two-Stroke Tech

500cc GP-Replica Tech Forums

Search  FAQ  Register Login
It is currently Tue Oct 23, 2018 12:28 am

All times are UTC - 4 hours [ DST ]




Post new topic Reply to topic  [ 93 posts ]  Go to page Previous  1 ... 3, 4, 5, 6, 7  Next
Author Message
 Post subject: Back in business - 7 years later
PostPosted: Sun Jun 11, 2017 3:48 am 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
I'm happy I can make good progress each week-end now.

Applied matt primary on the tank.
Bumps and dents are well seen now :smt005 .

Image


I painted the cylinder heads with engine black paint.
The finish is not great, but the casting of them was not vert smooth either, so this is not surprising.
Maybe I'll redo them.
Image


And I closed the crankcases with the new crankshafts.
Image

Image

That was my first time opening an engine.
I was a bit afraid before doing it, but this is finally accessible if you're hands on and have minimum tooling.
Result is great, the crankshafts rotate super free.


Last edited by Kalim on Sun Jun 11, 2017 7:04 am, edited 1 time in total.

Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Sun Jun 11, 2017 3:55 am 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
I have questions.

What is the purpose of the rubber parts that insert at the bottom of the cylinders ? Just filling the space of the casting ?

And on the top crank, gear side, what it the purpose on the parts that goes next to the bearing ?
Round and many holes in it, I think it is called "flywheel" . Why didn't they use a simple bushing ?


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Tue Jun 13, 2017 3:54 pm 
Offline
*****
*****
User avatar

Joined: Fri Dec 30, 2005 7:01 pm
Posts: 2222
Location: CAMBRIDGE,UK
Have a look at this link about the rubbers............................


viewtopic.php?f=3&t=9736&hilit=47X1135500

Steve


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Mon Aug 28, 2017 8:07 am 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
Hello,

I will send steel parts for surface treatment, so I wanted to collect all of them.

I managed to remove the steel crooked hose out from the thermostat case, but there is no o-ring nor gasket doing waterproofing between the two ?
Do you think sealing is done with gluing,or just pressing ?

Now I see that the aluminum thermostat and its steel hose is only one reference. Maybe it is not supposed to be dismantled :cool: .


Attachments:
P7160331.JPG
P7160331.JPG [ 204.25 KiB | Viewed 2246 times ]
Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Sat Sep 02, 2017 4:55 pm 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
Nobody knows how it is supposed to fit ? Press fit with some Loctite probably. That's what I'll go for.


I had a look at the gearbox today.
First time I open an engine that deep. That's quite easy to work on this engine. Although they made crazy design choices at some point, they globally did a good job in engineering !

Gearbox is in great shape. No mark, everything runs, turns, slides smooth.
I wasn't worried, these gearboxes are known to be over-sized.

But as per the upper engine case, the seal plane was slightly damaged in some areas.

Image

Image


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Mon Sep 04, 2017 6:40 am 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
The gearbox is back in the engine, but bad surprise, the screw that holds the bracket for the "star selector" has broken inside the case :mad: .

Image

Any advice is welcome :grin: .
I think I should drill a very small hole in the screw, and then drill bigger and bigger until it comes.
What do you guys think ?

Thanks.

David.


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Sun Sep 10, 2017 4:01 am 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
Nobody ?

Well, I'm almost there.

Drilled at 4,2mm, the screw is M6.
Image


It is just flush to the aluminium threads in some portions...
Maybe have to drill at 4,5...4,8, and I'll see what it does.
Image

Image


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Sun Sep 10, 2017 5:28 am 
Offline
- - - - -
- - - - -

Joined: Thu Nov 17, 2005 7:12 am
Posts: 1383
Location: Leicestershire, UK
Hi Kalim,

I think you're working on problems that most people on this forum haven't had to deal with so you're not getting any answers - however it's great to see your progress - thanks for sharing.

Cheers
Paul


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Mon Sep 11, 2017 8:43 am 
Offline

Joined: Mon Nov 16, 2015 1:41 pm
Posts: 423
rd84 wrote:
Hi Kalim,

I think you're working on problems that most people on this forum haven't had to deal with so you're not getting any answers - however it's great to see your progress - thanks for sharing.

Cheers
Paul


Agree with that...keep up the good work mate.


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Mon Sep 11, 2017 12:56 pm 
Offline
- - - - -
- - - - -
User avatar

Joined: Sat Feb 04, 2012 7:36 am
Posts: 2538
Location: Eastern Ontario Canada
I've done similar work here. You really need a pneumatic drill to do good job. The speed is essential. Start with a small drill bit and get progressively larger. Finish with an extractor (easy-out, etc).

Left hand drill bits are helpful. They will often remove the broken screw as you drill.

_________________
1985 RZ500 1GE Spec
1985 RZ500 47X Spec Project Bike
1986 RG500 ATR
1986 NS400R
1987 TZR250
1988 Honda RC31
2007 DL650 VStrom
2014 Triumph Thruxton Modified


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Sun Oct 15, 2017 4:58 am 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
I managed to save the threads in the engine housing. :cool: .

And I put the engine back in the frame, so I can check what shock lenght I need, to fit the moded R6 swinger.
I need a bit more than 295mm.
The Nitron lenght is 294mm +5/-2 , I'll probably go with Nitron :smt004 .

Image


And I reassembled yesterday the valves in the cylinders.
The valves had too much clearance. Bushes were worn out, one was also broken, its collar is snapped off.

So I had new valves bushes made, based on standard bronze bushes. (Thanks dad ! :mrgreen: )
The inner bush can be longer than original, to improve guiding and reduce wear.

Lenght 7mm can be 13mm for the bushes on the internal side.

Image

Image

It still gives enough room to fit the valve seal.

Image


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Sun Oct 15, 2017 10:04 am 
Offline
- - - - -
- - - - -

Joined: Mon Mar 07, 2016 6:55 pm
Posts: 252
Location: Maidstone, Ontario
Nice, I had to do similar work to mine. Looks like the flat on your valve is chewed up? As were mine. I set mine up in a V block on a granite table and indicated them square to the world based on what was left of the original flat. I then clamped them in place, welded up the damage and re-milled the flat back to original surface.

_________________
Shake "N" Bake!


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Sun Oct 15, 2017 11:14 am 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
The four valves all have a very worn flat.
I was still wondering if will should do what you're saying. You are probably right, I should do it while it is disassembled and accessible.


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Wed Jun 20, 2018 4:50 pm 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
Hello guys, this is to let you know the project still moves on.
I will put this bike back on the road, one day. But I will.

Engine is reassembled, everything runs smooth :smt007 .
The rebuild was definitely an elaborate job, but with patience and calmly, I think I made it.

Image


And then now it is back in the frame, ready for final assembly.
The rims are still brand new, but dust comes definitely quicker than I assemble parts.

Image


I didn't mention I purchased a Nitron shock.
What a beauty ! :shock:

I sincerely didn't expect that high level of quality.
I'm a mechanical engineer, I'm use to see nice machining. This Nitron shock is really great stuff !!

Image


Finally, I just broke my piggy bank, and ordered a set of Jollymoto pipes, GP style and aluminum cans.
Can't wait to install and see them on the frame !


Cheers from France !
David.


Top
 Profile  
Reply with quote  
 Post subject: Re: Back in business - 7 years later
PostPosted: Sun Jul 01, 2018 1:34 pm 
Offline
User avatar

Joined: Tue Aug 14, 2007 2:14 pm
Posts: 232
Location: France - Nantes
Hello all, it seems to be very quiet here.
I received the pipes last Friday, and of course I couldn't resist to install them this week-end.

I have wondered for long time which pipes to go with, Jim Lomas or Jollymoto.
I like most the Jollymoto look with the smoother shape. The JL are more angular. But also the Price was a big constraint.
I've read many comments recently here about the mouting of the JL that is not perfect, and the delivery time also being long.

I'll do this project once in my life, and could afford them last month, so go for the Jollymoto.
And I don't regret at all. I received them in 10 days. The assembly is great, it works perfectly, all mounting holes align perfectly.

Also thanks to Matty who has the same swinger, and who confirmed me the Jollymoto stuff leaves enough clearance around thé swing arm :grin: .

I won't use the standard rearsets, and don't have the special ones yet. so this mounting is not done.
The pipes are supplied with a long straight flat aluminium bracket. Maybe I could use it, but the finish of it is really bad.
Anyway I didn't expect to have a bracket delivered.

Image

Image

Image

With the Nitron shock.

Image


Last edited by Kalim on Sun Jul 01, 2018 4:20 pm, edited 1 time in total.

Top
 Profile  
Reply with quote  
Display posts from previous:  Sort by  
Post new topic Reply to topic  [ 93 posts ]  Go to page Previous  1 ... 3, 4, 5, 6, 7  Next

All times are UTC - 4 hours [ DST ]


Who is online

Users browsing this forum: No registered users and 4 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Search for:
Jump to:  
Powered by phpBB © 2000, 2002, 2005, 2007 phpBB Group