RD 350 LC Hybrid build

[hardhatharry]

Started the build by stripping the YPVS engine.

Not great news first the pistons are looking rather scored and very second hand





So then taking off the barrels resulted in a broken engine stud (see other thread)

Anyhoo took off all the gubbins and split the case all mains are shot and conrods are needing replacement too



Looks like one of the pins missing off the end of the crank has caused some scoring on the case but I think that should be ok.



I noticed the selecter star wheel seems weak so I might as well change the spring and I also noticed that there are a number of bearing that need replacement too.

Time to open the wallet

[Deleted]

good luck harry, ive just finished one so have a rough idea whats ahead of you, take your time ,dont count money and everything will be ok and if you stick to it you will have a stunning bike to show,

[hardhatharry]

Ok tonights job get the stud out

rdlccrazy.proboards.com/index.cgi?board=general&action=display&thread=16347

so first get the dowel out that surrounds the broken stud but its stuck fast even though there has been WD40 down the hole for two days so liberal heating via a heatgun and liberal use of the mile grips still nothing.

Finally welding a bolt to it finally gets it out but it needs replacing

Onto the broken stud, first flattened the surface using a dremmel and a stone then WD40 and a small drill bit to make a small central hole. More WD40 and a bigger drill bit and a bigger hole, again bigger drill bit and a bigger hole.

Attempted to use a stud extractor bit it aint budging so up again on the drill bit and another hole

Its now looking better



Now ran a tap down it



and its as good as new

[hardhatharry]

My care package from Grampian arrived today



Luckily the crank only needed bearings, conrods and seals so thats looking good



The boreing man didn't look happy he wanted to know who bored the barrels last (before my ownership). He said the barrels weren't straight and had been bored in opposite directions so they had to be bored from +1.25 to +2.00





He also said the powervalves had been hitting the pistons and has left instructions on how to trim the powervalves which was nice.

So there are seals, little ends, gudeon pins and some bearings in the box too.

So lots of new bits to put in.

[Deleted]

well done sorting out your broken bolt, looks like you will have it back together in no time

[fatbloke]

Well done, i'll be watching the build too

[Deleted]

Looks like you picked the right man for the re-bore. Who did you use?

[hardhatharry]

Grampian Motors www.grampianmotors.co.uk/

Famous round here for two stroke stuff

[2cl]

Always nice when a box of parts arrive.

[hardhatharry]

Well was supposed to be going to Mallory for 1000 bikes this weekend but change of plan meant I was going to go to Llandegla to do some mountainbiking but severe weather warnings and 40mm rain in two days expected put pay to that so I think I will crawl into my cave and fettle some bikes instead

[hardhatharry]

£90 spent on gearbox bearings hopefully arrive here tomorrow

[mark350lc]

The bore man at Grampian never looks happy. It usually goes something like 'What have you brought this pile of junk for'. Think its just his sense of humour. I've also never known him to go just one size up on rebores, but I guess he knows best.

[Shytalk]

How much did the crank work and rebore work out to Harry?

[hardhatharry]

Just short of £300 as the crank didn't need webs but has new conrods. There is also liitle end bearings, gudeon pins and circlips in there too plus some seals.

[hardhatharry]

Spent all night cleaning the cases up, nearly there

[hardhatharry]

Well bottom half of the engine back together, would have got a bit further but seem to have lost the main crank bearing half ring so Granbys to the rescue and one sent out in the post for tomorrow (like Granbys alot!!!)

Also ordered some strenthened powervalve thrust plates from NK racing as one of mine fell apart on the disasemble. While I was on the NK racing side was considering an offset front sprocket for the GSXR400 swingarm but I dont think we are there yet.

Pretty aint it

[OldMedic]

Keep up the good work...

[Norbo]

Its coming along nicely mate .

[billy]

Nice work so far mate, gonna be a nce engine.

PS: Am I the only one that enjoys spinning the drive shafts (and the crank) when the engine cases are open like that? It's amazing to see all the gears go round and round. It's so smooth and slimey and nice.

[Deleted]

no your not billy, i liked to play with it as well, , playing with the crank was like milking a cow

[raven13]

so you both like to hide out in your sheds cranking it.
you guys will go blind,lol.

[Deleted]

they arent called strokers for nothing

[hardhatharry]

Just need to grind back the powervalves so they dont foul the piston, the gap is currently 0.2mm but needs to be 0.38mm

[Norbo]

thats some grinding youll be seing the pin then.

[hardhatharry]

Nah, all ground back and sorted now.

[hardhatharry]

Anyway finally got some time to go back in the garage.

Got the pistons on surprisingly easily but the circlips were very springy luckily I didnt loose one when they made their bid for escape.

Applied Moly grease to the Powervalve bushes and O rings and fitted NK raging thrust seals but then I found someone has retapped one of the thrust seal screw holes a size bigger so I will have to modify the seal, seem like a good reason to stop for the night and celebrate with a vodka and coke.

Anyway loads of pictures below, someone let me know if I have done something stupid.

[hardhatharry]

Quick update

Frame is back from the shotblasters

Not rusty anymore

[hardhatharry]

Some repair work needed

[hardhatharry]

Engine now all together and making a satifying p-plop noise when its turned over

[hardhatharry]

Now I need to figure out how to fit this



and this



into this



using this



and a bit of welding with 4mm plate