But will it start?

Done!

A brand new white gaz tank and fuel filter are installed, the flywheel is back in place and the cover is on. I was even lucky enough to find a coveted engine cover a couple of months ago, so the bike is just about complete.

But will it start?

Next week, I will fuel it and set the points, and attempt to start it, and brake it in a bit, if the gods of the gas engine are with me!

Pumped up!

We're nearing the end of completing the engine rebuild. One of the last main component is the fuel pump that needed a cleaning. In the pumps are two glass beads that allow fuel to get in and get out. These need to be free and move at will. When cleaning the pump, the top one is easy to take out, the bottom one is nestled between two plastic 'seat'.

I could not clean the bottom one without disassembling the pump (top left) and I do not have replacements seats. So I looked through my inventory of parts and found another pump, cleaned it and it was ready to go. I changed the membrane and blasted screws.

Not pictures, the fuels lines were cleaned and mounted back at the same time as the pump.

Next will go a new gas tank and fuel filter, the fly wheel and a new fly wheel cover.

Carb your enthusiasm!

Next step in the engine rebuild, cylinder head and head gasket, decompressor, carburetor...

First a new head gasket and exhaust manifold gasket

 Cylinder Head bolted on with the new Spark Plug, a new spark plug wire..

And here is the Carb!

Next, the fuel lines and pump will be cleaned and reinstalled, and we'll be essentially done with the engine..

Something Old, Something New...

Something Borrowed and Something Blue! The engine continues to be back together. The front fender in now in, a new spark plug wire and the stator is back. Next is the engine top pieces, Cylinder head and gaskets, the carb.. Pics to come!

Putting the puzzle back together

Now that all the parts are clean, it is time to put that engine back together, first I heated the block and using a new bearing, installed the bearing and sealed it. The new bearing is a double-sealed so it won't need lubrication unlike the old one on this picture

New set of gaskets will find their way on the engine block

The block gets the crank shaft and side plates that attach the engine to the bike frame:

Piston is installed and the cylinder for fitting before closing the case with the oiled gasket

Here it is with the engine top end and gaskets secured

View from the other side with the rolled installed, the long screw is preventing the crank from turning when tightening the bolts securing the roller and the clutch

And here is the clutch

Take me to the cleaner!

Glass beading has been my main occupation lately:

The engine block, Before and After:

The Stator, Before and After

Here is the other side before and after, everything was taken out, cleaned, checked and back on the Stator, just missing is the Spark Plug wire that needs to be changed with some new cable

Engine down!

The engine works continue, now that the top part of the engine is clean and ready to be reassembled. 

The lower part is next: 

- Remove the fly wheel

- Remove the stator

- Remove the clutch

- Remove the crank shaft and bearings

- Clean all

- Replace the bearing,

- Reassemble everything

This is what we started with:

The first step is to take the flywheel out, you need a puller to do this since it is pressure set on the crank shaft and screwed. 

Once this is out, it's the turn of the Stator and Points

Then comes the clutch and roller

This is what the engine block looks like before pulling the crank shaft

And it's out

Time for clean up!

Put a ring on it!

After the cylinder, the piston deserved a little clean up. One of the rings is stuck, no big deal, this should be easy to get back to working condition. This is what it looked like the first time I opened the engine, diiiirty:

The first two rings came out fairly easily. The third one however, is glued by the burned oil. My trusty welding torch helped me and the rings came out, until.... it broke while I was moving it around the piston... of course...

so I cleaned the piston well anyway, and dug my pile of parts... 

and I have some new ones, all is well!

Next I need to remove the flywheel, the electric components, and it looks like I am heading for a full rebuild! Lucky you!

Is it a cube, is it a pyramid? Nope it's a cylinder!

Next on the block is the cylinder and the exhaust pipe. These two were in dire shape, rusty and cruddy. 

A good clean was in order, so I started by removing the leftover gaskets, cleaning the burned oil and then off to the blast cabinet we go

After that it's time for heat resistant paint, and here we go, looking all smart!

It will take 7 days to fully cure before the cylinder can go back on the engine, so that should leave time for some other items to be cleaned up!

A Clean Head..

A little bit of work tonight to continue the journey. The cylinder head was as dirty as it get, that's an understatement to say the least... gunk, gunk, gunk..

After taking the decompressor apart, a good scrub with a brush first, then a scrub pad with soap, then the bead blasting, and another wash for good measure. Same steps with all the parts of the decompressor. Oiling the decompressor and reinstalling everything showed that there is no breaking in necessary, the gaps are good.  The spark plug went to the garbage and is being replaced by a New Old Stock Marshal-Corindon V36A which where installed in the factory.

Carburator

The Carburetor will be the first step in the engine rebuild, it is always one of the sources of issues and has to be cleaned thoroughly.

The before

Taking it apart

The filter will be replaced, all the pieces cleaned and the carb body will be beadblasted to give it a new lease on life

Here is the after, all ready to get back on the engine when everything (else) is done