Rebuilding motorcycle after timing chain skip 62K Km

[Claudiu]

To boldly go where no man has gone before....

Thank you. It will be useful soon. I will also need a large collection of harness routing pictures.

 

[Steff]

Hu, just did chain and tensioner. Peace of mind and all that. 34k on the clock. It's the old Gen 1 where the tensioner oil pressure fails. Anyway, done at £320.

 

[Claudiu]

New barrels block, new cylinders and new piston rings kit arrived. Preparing to start assembly process. Since I left the conrods installed on crankshaft (I didn't want to open crankase) AND decided against pushing the pistons up the bores from the bottom ( scalloped barrels come with high risk of damage in DYI conditions)... I will install the pistons in the barrels the connect the conrods in sequence. So this is the theory, let's see the practice in upcoming weeks.
Fun stuff: used Claude AI to research tools techniques and best practices. Took some time and quite some loops to filter out dead ends. Here you have the info, hoping it works for most DYI-ers and save time. It took itself seriously when I asked to summarise everything into a work instruction. Now I go after my aluminium ladder to build myself an overhead crane.

 

[Rick111]

Wow that is some project you have going . Subscribed for updates .

 

[Rick111]

Did you fire it up yet ?

 

[Claudiu]

Did you fire it up yet ?

Long way to go. I tried to install the pistons but the tall steel band compressor I have is nor suitable for the job. I need one with the pliers. For these pistons diameters there’s no dedicated sleeve but only an adjustable tappered one which I couldn’t find in stock in Europe. Once I have the pistons inside the block the next big challenge will be to connect them to the rods.

 

[Rick111]

One bolt at a time do it right do it once. Please keep the forum updated on progress. Happy motoring .

 

[Claudiu]

Info sharing for those who need: Piston ring compressor 4.250" - 4.340" made by Summit Racing in US. Part number SME-90A4250.
Rocket 3 cylinder bore is ~110.2mm, ~4.3385".

 

[Claudiu]

Gave the robots some work to do while waiting for the piston ring compressor sleeve.

 

[Claudiu]

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.