Rebuilding motorcycle after timing chain skip 62K Km

[3-D]

Tensioner blade plastic slide disconnected. I am chasing a rattle on hot start since four years. Will see if this was the cause when I will start the engine.

Is the bike living in your car? I sure hope you remember how it all came apart...

 

[Gerald]

For info the manufacturing orientation of the circlips securing gudgeon pins. It should be possible to slide in the gudgeons through the bottom scallops of the barrels. I am not sure how to fit the circlips though, it will be a narrow space and fingers are not pliers. Thimbles, custom made tools, any creative ideas? Pictures show the old pistons at 62K kms after pulling the barrels.

You roll circlips in one spiral at a time, always had piston in my hand or on table when installing circlips.

 

[Claudiu]

Is the bike living in your car? I sure hope you remember how it all came apart...

It moved into the garage, cupboards and boxes . I built myself worksheets and instructions. With pictures and hand notes. But the most annoying is that the bolts and nuts are together…

 

[Claudiu]

You roll circlips in one spiral at a time, always had piston in my hand or on table when installing circlips.

In this version of events I left the conrods on the crankshaft to avoid splitting the crankcase. I can install one circlip and the piston rings on the table, then the pistons go into the barrel and I lower the barrel to fit the gudgeon pins and the second circlip for each piston. I need three hands, a thin tentacle and a makeshift overhead crane… or more tentacles