MY F2 Rebuild

[mellow]

ITS TINY how am i sposed to see that with my eyes

[Norbo]

rufarse said:

PMSL Pablo

Right then folks, the swinging arm is ready

After:
- wasting a day polishing the damn thing,
- taking it back to square one in order to get a key ready for priming
- spraying it, only for Zeb to get his hands on the spray can
- stripping parts of it to get rid of the runs (see point 3)
- getting another key, priming, spraying and lacquering
- hiding all spray cans

we are ready!!!!!


(sorry it's so big, I did resize the bloody thing!)

Bit by bit a job gets done . Every little job counts . Befor you know it you will be thrashing all over the place .

[zebrd]

admin said:

rufarse said:

PMSL Pablo

Right then folks, the swinging arm is ready

After:
- wasting a day polishing the damn thing,
- taking it back to square one in order to get a key ready for priming
- spraying it, only for Zeb to get his hands on the spray can
- stripping parts of it to get rid of the runs (see point 3)
- getting another key, priming, spraying and lacquering
- hiding all spray cans

we are ready!!!!!


(sorry it's so big, I did resize the bloody thing!)

Bit by bit a job gets done . Every little job counts . Befor you know it you will be thrashing all over the place .

Were getting there slowly, engine, carbs, brakes and bodywork left to sort out.

I think rufarse has sent a picture of a swingarm for a hamsters wheel. ;D

Hey Norbo can you get side and centre stand springs mate?

[rufarse]

pablo said:

i'll get my magnifying glass ;D ;D ;D

hmmm not sure whats gone on there, I apologised for the size cos it was huge when I previewed so resized the bleeder, how's about this one, any better for ya?....

[zebrd]

Bike is now on 2 wheels. With a wheel in temporarily untill I get the real wheels from powder coaters.

Gonna relax and have a beer and crack on with the crank tomorrow night.

[rufarse]

minesatwin said:

yer, but even if they were to go there seperate ways, they would still have enough parts to make a bike each!

ROFLMAO - this is true, plus with a bit of mods, apparently his spare engine will fit in my Teazer - so he knows he has to behave!

Norbo - the bolts are sprayed with left over Corsa blue! the subtle touch huh? I'm pretty certain I have the delight of spraying the casing bolts blue too - along with a few little intricate displays of my masking tape capabilities!!!!

[zebrd]

admin said:

Well Zrbrd , Thats realy coming along now. Looks very clean. i see you have fitted some blure alloy bolts and have you painted the swinger nuts blue to match . Its ther small bits like that i like to see. Are you going to fit blue alloy bplts to the casings aswell or where you just using a few bolts you had knocking around.

I havent painted the swing arm bolts as Ive ran out of spray paint. I need to get some more at the weekend and do the swing arm bolts. Yes I will be painting the crankcase cover bolts blue as well. And the YPVS on the cylinder head will be blue as well.

Ive sent you a private to Norbo.


Talking of the weekend, got my brakes to sort out, then we are nearly there.

[rufarse]

Hey Peeps

Just a quick progress report before we bugger off to the pub! ;D

PJ Prox have done the barrels already, as we found out yesterday when we dropped off the crank.

Gotta order some extra stuff, i.e. oil seals from Norbo

Today we have mostly been fitting the airbox, stripping the crank cases and cylinder head which I've sprayed now (good old PJ1) Gone a bit arse about face cos I've yet to polish the YPVS badge on the head, but we'll cross that bridge when we come to it (probably tomorrow night)

Rain stopped play a few times, but here's a few piccies to keep you entertained:

Crank case before:

Crank case after:

Inside crank case:

Cylinder head:
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Bottom crank case:

wiring loom and airbox just for good measure:

and a side profile:

[rufarse]

Good thinking Mellow.

The plan was to paint the YPVS bit blue (same as the bolts), and then spray the YPVS bit, hence doing it a bit backwards.

That's one of my jobs today (the joys of working from home) I'm pretty nifty with the old craft knife and masking tape, so we'll see what the outcome is.

[zebrd]

I have a question

Im fitting all new seals in the engine, Im aware the crank seals have to be fitted before putting the crank cases together, but can I fit the kick start seal, oil pump seal, water pump seal, front sprocket seal after the cases are together or is it best to do all seals whilst the crank cases are apart?

Cheers

Zeb

[mellow]

i did all mine while it was apart much easier

yup think i finally got the clutch adjustment remedy sorted ta

engines in back wheel n chain are all in permanent now

[zebrd]

Von those wheels are temporary, were in the process of respraying and polishing some wheels and then putting BT45's on them.

[zebrd]

Guys

Now then, as I say Im rebuilding my engine at the weekend, is there any precautions to take before starting it? Because Im sure someone said to me to put two stroke oil down the barrels before you start a rebuilt engine......or did I dream it? ;D

I know for a fact that I must make sure the oil pump is hunky dory and that there is oil getting through.

[alibongo]

It wont hurt mate, you can always take your filters off and smear 2 squeak oil on the carb slides till you are sure the oils getting through from the pump. Making sure you have bled said pump first. ;D

In fact you may as well do just that.
Start her up, smear oil, hold oil pump fully open untill you are satisfied. (dont forget to keep your eye on the ammount of smoke coming from your pipes, if it starts to dissappear smear a bit more oil on the slides)

Get her up to temp, switch off, let her cool, re-tourqe head bolts, game on.

[mellow]

as long as all the bearings and ends were coated in 2 stroke when fitted u should b ok.smear sum 2 stroke oil round the bores and also round the rings.........but dont overdo it

put in fluids................check oil pump cable adjustment..........hold cable fully out.............kick her over n hope it starts. ;D

thats all i did n mines fine m8

[zebrd]

Ive got the crank and barrels back from Prox, will post a piccie up later. They look superb. Just got to spray the barrels in PJ1 and then start rebuilding the bottom end.

[jacobeana]

Put some two stroke oil in a pot use a small paint bush and coat bores crank big ends smallends

Will smoke when u first start up but will be ok ;D

[zebrd]

Right then some piccies for you.

My rebuilt crank.



The barrels before being painted.



The bottom end in the process of being rebuilt.



I will finish the rebuild of the bottom end tomorrow and the barrels will be on in the week and then the engine is going in the bike. The next job is the the radiator and pipes etc and then connect evereything up so the engine can be started.

[mellow]

lookin good m8.
u have the barrles blasted i take it or did u paint strip em?

i like ur tools...............bottle of TTS and a tin of carling ;D

[zebrd]

I attempted to respond at 4.30 this morning, but the missus warned me I was typing bollox!

Barrels have been shotblasted by Prox Engineering (included in the rebore price )

Don't worry Mellow, Rufarse has already pointed out that the ties have to go!!

[zebrd]

If all goes to plan, the engine will be in the frame and hopefully running at the weekend.

Ive ordered new engine oil, got TTS two stroke oil, got to get some plugs, ordered 2 new main jets for the carbs and new water and oil pump seals.

All I have to do now is fit the woodruff key to the crank, fit the oil and water pumps, put the cases back on and fit the cylinder head. Then fit the engine in the frame and connect everything back up.

So fingers crossed the bike may be alive again at the weekend. Here's hoping.

[rufarse]

Right then folks the engine is complete, well give or take a couple of things to finish off. Still waiting for engine oil to arrive and a couple of other things but it WILL be running next Saturday (don't worry Mellow we will film the nailbiting event for your entertainment!)

Here's a snapshot of the engine before we took it apart!


hopefully, this looks a little bit better - it's definitely cleaner


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[vin]

Looking great not long now

You going for chrome,zinc plated or standard head bolts.....stainless ones would look

[mellow]

ebay m8...............£42 each.expensive but they make ur bike explode well.....dont they pabs

[zebrd]

vin said:

Looking great not long now



You going for chrome,zinc plated or standard head bolts.....stainless ones would look

They are the standard bolts sprayed blue to match the rest and the blue ypvs on the cylinder head.

Thanks for the comments guys.

[zebrd]

mellow said:

nice one zeb....................its good to see u got urself a pair of them special spark plugs to ;D

Thanks mate. Took me ages to get them "special" spark plugs they held me up for ages. ;D

[zebrd]

Right then folks, to bring you up to speed. The engine is the frame. (at last) ;D But had a big problem getting the temperature gauge sensor (right little bar steward it was) out of the cylinder head (bodge no 7063 by previous owner). I had problems getting the clutch to sit right, thankfully had a spare cable unused which eventually went on but after readjusting the clutch settings and taking the crankcase cover off yet again.

So Ive got to put the cylinder head back on, the radiator back on and the carbs and recheck the wiring before connecting the battery as my assistant rufarse didnt connect all the wiring around the headlight.

So will be working on the bike throughout the week and will keep you posted on our progress. Its a slow process but we are getting there.

[zebrd]

Here is where we have got to.

[zebrd]

There is two stroke running through the bike now. I didnt notice until last night that the previous owner had rounded the bleed screw (what a surprise) so out came the chisel and hammer and I managed to get the screw moving. Need to get a replacement now.

Cylinder head is torqued up now, just got the radiator and carbs to do tonight. Then put engine oil in and water.

Tomorrow I better get some petrol for it (might help eh!!! ;D)

[zebrd]

Ok Ive got the carbs on and Im trying to balance them. Ive used this method.

www.mawsleyvillage.com/ look under the section "how to" and select balance carbs.

Ive put 2 small pieces of wood against the needles and I get no movement with the wood when turning the throttle. Ive touched the needles with my finger and moved the throttle and I can feel the needles move.

Can anyone tell me what Im doing wrong? Or if there is an easier way to balance my carbs. Also my throttle doesnt very smooth at the moment but Im presuming this with get better when the carbs are balanced.

Ta

Zeb