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great thread

Evening All

Update time......

Made quite a bit of progress today. I had bought some gearbox shims of various thicknesses during the week, so the first job was to remove the end-plate and try and get the end-float tolerance down. Originally it had a 2.0mm shim, but that was out of the 0.30mm tolerance, so I fitted a 2.2mm shim that I had spare. This brought it into tolerance (0.30mm), but only just, so today I fitted a 2.3mm shim which has brought it down to 0.19mm. I'll settle for that!

With the gearbox set up, I fitted a new seal into the drive-side bearing retainer. I have fitted a drive-side bearing which has a built-in seal which will prevent any gear oil from passing through. The gasket has also been fitted and sealed - belt-and-braces The seal retaining plate was fitted with new socket-cap bolts which were Loctite-ed, torqued up and also centre punched to prevent loosening.

Next job was to look at the new crankshaft and check to make sure both webs were running true prior to fitting. This was done by setting it up between centres in my lathe and using a DTI gauge to check for any run-out. This was all good, so I fitted the bearing track to the tapered side. One thing I forgot to take a pic of was the fitting of the Woodruff Key. This was taken out of the old crank, then fitted to the new one.

With the crank ready, it was time to fit the new seals and bearing into the mag housing. Once done, the crank and mag-housing were fitted.

Next it was time to fit the clutch inner and outer bells, bearings, chain guides, cush-drive / front sprocket assembly and drive chain.

While all this was going on, I had the new clutch plates soaking in gear oil and to complete the transmission assembly, the clutch springs and plates were fitted and held in place with a new circlip.

To complete today's work, I started fitting-up the chaincase cover with the kickstart assembly. This all went together with a new O-ring, washer and circlip and also a new pinion retracting pin as the old one was nearly sawn in half

I would like to complete the engine during the week after work, but if not, it'll be at the weekend. Stay tuned for the next update and thanks for the comments.

Anyway, enough of the dialogue, here are some pics!
Jim

New shim fitted:


Gearbox and end-plate fitted for the last time:


Seal retainer plate fitted:




Mmmm, sexy! :


Checking crank webs for run-out:


Old bits laid out in order:


New bits ready (spacer ring not shown but was fitted):


Bearing track fitted to crank:


Mag-housing fitted up:


Crankshaft in:


Mag-housing fitted:


Back to the transmission:


Ready for clutch plates:


I didn't take a pic of the cluch plates being fitted

Kickstart parts prior to cleaning and fitting:


And how it sits until next week:

I hate threads like this......... makes me want to take mine to bits again and play.

I am kidding This looks all very methodical and organised. Nice work.

@ Nigel. S - Thanks for the comment

Well, it's that time of week again, and I have yet another update. To tell the truth, I wanted the engine back in the scooter today, but things took a tiny bit longer than I hoped. I'm pleased to say, the bulk of the rebuild is now complete. All that is left to do is fit some new rear brake shoes, inlet and exhaust manifold studs, inlet manifold and carb and the exhaust. Oh and the cowlings

This time next week I'll have it bolted back in the scooter and hopefully it'll run lol.

Today saw the completion of the chaincase cover, the clean-up and fitting of the clutch lever and gear linkage arms, fitting the barrel studs and barrel, fitting of the piston, checking ring gaps, fitting the stator and setting the ignition timing.

The next engine on the bench will be a Monkey Bike engine But obviously I can't post that lol. There are however some small jobs to do on the scooter itself. The first being the fitting of new fork link bushes and bump stops.

I'll let the pics do the rest

As always, thanks for stopping by and having a looky.
Cheers
Jim.

Clutch release arm parts:


Scrubbed up well:




New drain plugs and breather:


Rear brake pivot and arm cleaned and fitted:


Gear change linkage and cable adjusters refitted:


Chaincase cover refitted with new nuts:


Head/barrel studs fitted:


New piston & rings:


Piston rings oiled and fitted:


Sliding the new barrel over the piston:


Barrel temporarily tightened and DTI setup to find true TDC:


There it is:






All marked up:


New head gasket fitted:


Head on:


Stator set and tightened-up:


Flywheel fitted and about to be torqued-up:


Wiring flange thingy fitted:


And there we have it! Just inlet and exhaust manifolds and studs to do:




Tune in next week to hear it run... hopefully.

Nice work and detailed pictures

Cheers Toddy

Well the snow didn't stop me today. I buried myself in the shed with the fan heater and rinsed some electric.

To finish off from last week, I fitted the inlet and exhaust studs, fitted the inlet and exhaust manifolds, cleaned the fan cowling and modified the head cowling so it would fit around the bigger diameter exhaust downpipe. Oh I also fitted new rear brake shoes.

With these bits done, it was time to refit the engine into the scooter. Once bolted up, I refitted the air box, fitted a new Scootopia SH1/20 carb and connected the CDI and rectifier.

I must say, the quality of the carburettor is just as good as the Dellorto - if not, better. I shall be buying one for my other LI.

Finally with all this done, it was time to try and start it. The video below is actually the second start-up as I wasn't sure just how many kicks it would need for the first one. I should've filmed the first start, it went on the third kick

I've just got to refit the floor board and a couple of bits. Next job is to re-bush the front fork links.

Anyway, time for some pics and of course, the video. Thanks for stopping by

Cheers
Jim

Inlet studs fitted:


Inlet manifold on:


Rear brake shoes and flywheel cover fitted:




Flywheel cowling cleaned and fitted with new grommets and bolts:


Head cowling modified to fit round new downpipe:


Exhaust fitted:


It's snowing lol:


Engine in:


Mmm, nice!:




And back on his wheels:


And the vid:

Great thread and lovely clear photos .
Thanks.

Sounds good it’s a great feeling starting them up after a rebuild , agree regarding the scootopia carbs just fitted one on a lads jet engine I’m doing great quality and fit I suppose the proof will be when they are running on the road

Job well done.

well done - doesn't sound great!

Looks and sounds great, I'd have stuck a standard clover leaf exhaust on that though, would look the dogs do da's

What a LOVELY sound . well done , credit to you .

G.

Great build thread & video ! well done

Excellent. Good work.

Superb thread. Thanks for taking the time to detail it all, the motor running sounds great.

Cgt75b