Engine rebuild

[paulmceleney]

the carbs look new looks good chris

[tlc]

Went down to Monsieur Cox`s today and collected my cases.

Nice job done and only £110. Pics tomorrow............with questions

[tlc]

Got the cases up on the stand today, had other stuff to do on Sunday so had a half day off, and started to clean out the threads.





I also cleaned out the base of the barrel studs which were basically still containing excess thread sealant.



It is satisfying to hear the crunch as the medium is dislodged after vapour blasting, although mindful of GEZ365 comment I was very thorough. I went through twice with the thread cleaner and used a fine bottle brush after each run through of the threads.



I then popped up to a customers premises to borrow his 150psi airline. I washed out all the threads and orifices with the bottle brushes as well as a parts cleaner brush and blasted hell out of the openings. It was satisfying to get even more medium out which I could tell was happening because of being peppered in the face.



I got the cases back home and checked the threads again which were clear.
I then did a dry build of the cases merely to have somewhere safe to store the oh so precious crank. I`m still waiting for the camchain from Jeff which should be here in the next few days and can then start to build in earnest.



One thing I will have to return to Mr Cox is the cam cover which looks like it has only had the first stage of blast, but I had forgotten to take some smaller bits so will do that at the same time.

[Steve S]

looking good Chris,enjoying watching the progress,keep us posted.

[Taffus]

As ever, in awe.....
must get my arse in gear and start.....the 1100

[Rob Lafferty]

Looking good!

Keep the pics comming as I'm going to see mr Cox later this week to pick up crankcases. Can use this link as a step by step guide - easier than reading a manual

[Ginger Bear]

Really good job so far Chris...... Will you take it out in the wet once you've finished it

[tlc]

I might let you overtake me on the build.

Then I can follow you

[Rob Lafferty]

Took lots and lots of photo's when it all came apart. If you get stuck or unsure, let me know as i will probably have a pic!

Aiming for ace cafe if not then the other kawa will have to do.

[mick znone]

nice job TLC, i thought you were a rider, didnt know you could get your hands dirty

[nanno]

I will follow this really closely... very educational.

Keep it up!

Cheers,
Greg

[tlc]

I had an hour or so in the garage and found that the 2 o rings for the oil pump and the case halves were in good condition. However................

I`m getting paranoid about reusing inexpensive parts so I`ve ordered some from Jeff at Z1 as I needed some other bits. On that subject why is it that inlet stubs are 1/3 less from him than Z Power ? After Jeffs excellent and informative post about the parts he sells I wonder. Also I cleaned up the little dowels which I had managed to extract with a snap on extractor kit. These are very finely threaded and tapered items that were just the job which with a little heat pulled the buggers out without difficulty.

Anyway I am a bit stuck at the moment because of waiting for Mikey to pull his finger out, I know Mikey.......I know . I spoke to him today and he is flat out with work which is great news `cause he is such a nice guy and a more thorough person you could not possibly wish to meet. Anyway the reason for my call was to say that I forgot to post a bag of upper case bolts so that`s my fault. Once the camchain comes from Jeff I can bolt the crank in and get everything ready for joining the halves together.

I`m getting a bit panicky that it will all take too long and I won`t be ready for the Ace in April because of my ineptitude and those whose services I use now being really busy, so lead times are longer than normal.

I`m sure it will all come together at the last minute

[mikey]

When it all seems hopeless suddenly it all comes together,
going to the platers tomorrow drop some anodising off chase yours up.

[bunnysZ]

that means you have some spare time then chris until your parts arrive... goody.

if its not back together by april you could all ways put the kawa badges on the jag and use that.

[tlc]

I got my last engine bits blasted yesterday and today the package arrived from Jeff at Z1. I was short of the o rings that go on the oil pump and crankcase half but ordered them from Z Power today. I also ordered some Kawabond, actually something similar which at £10 per tube is £60 less than the genuine article. I`m assured it`s as good as.
I will get the camchain in over the weekend and just now have to await delivery from Mikey of my bolts.

One question on the o rings is that there is a flat side and a tapered or rounded side. Is it right that the flat side faces down ?