Où Est La Second Gear?

[squirrel_hunter]

There was a small MoFo Mechanical Expedition this weekend to find 2nd gear at Cassa Del Strechie. 2nd gear was last seen around the summer of 2006, it vacated the bike for almost a year before returning. However the return was more like a fleeting visit and shortly after it decided to vacate permanently. But its worse this time as 3rd gear accompanied 2nd. Sensing a trend 4th gear has also been known to come and go as it pleases.

http://i153.photobucket.com/albums/s216/squirrel_hunters_photos/23022008026.jpg

So the expedition proceeded bright and early Saturday morning. Who am I trying to kid!?! it was mid afternoon before a spanner was raised in anger at a 'Cat. And after a brief excursion for Breakfast around 4ish the engine was removed and the expedition expedited themselves to the nearest pub by 9.

With much tomfoolery, Strechie, Myself, Mac99 and the lesser spotted Beenz finished the day with a bike in a not so unfamiliar state...

http://i153.photobucket.com/albums/s216/squirrel_hunters_photos/23022008034.jpg

And as one would expect, a bunch of MoFo's cannot go for a drink without some notable occurrence. And there were many. However, the photographic evidence is not as clear as one would have hoped; so Strechie can hold is head high knowing that no one will see his little 'Water Sports' adventure and Mac99 will not be teased for going to bed with an absolute Dog.

The Morning came, and went, but with many mugs of Tea work resumed. And by the end of the day the 'Cats engine was nothing more than a collection of well annotated freezer bags. There is however still much work to be done but signs of 2nd gear have been found residing in the sump.

The expedition is set to reassemble once Strechie has finished with the Baby Oil...

[Xan173]

Baby oil? That must be the Cheryl effect.

[Viper]

The cat is Scrap :smt081:smt081

[_Stretchie_]

You bast... Oh.. 'Scrap'..

I'll let you off

[_Stretchie_]

I have now borrowed Xans grinder and removed the front sprocket nut.. long story short (although some will remember) the front sproket was welded on.

Tried to split the engine last night after removeing the clutch (to which we were delayed after finding some of the bolts the Haynes manual said to remove using a socket extension were actually hidden behind other bits of engine which had to come off apart and such. Now I just need to remove the piston heads and I'll be in there and ready to order the parts

[lemmings999]

which is taking longer to fix, yours or mine

[_Stretchie_]

Alright Lemmings.

Mines been 'in a condition' since July 07.. What about yours..?

[lemmings999]

mine's been "off the road" since i went sliding down the road in sept 2006

[_Stretchie_]

You win

; )

[squirrel_hunter]

As I understand there are 1's or 2's of you out there watching this thread with much anticipation of an update (optimistic I know), so here's an update...

The engine has been split and the offending cog replaced. All has been cleaned and this weeks expedition was to be - slip the engine back in and go for a little run. Things were not to run smoothly...

During the week Stretchie had problems with various engine components and a number of visits to Fowlers parts counter was made, he has his own parking spot reserved for such occasion now. A particular bearing prevented the removal of a washer, but after 100 tonnes were exerted on said bearing the washer was liberated. Thus by Saturday all was ready for assembly.

The gears were assembled and placed in the crank case, the crank was added, gasket was applied, and both case half's were mated. All bolts that were numbered on removal were replaced in order, hand tightened, and then torqued. Unfortunately there was a mild misunderstanding of torque settings and a bolt that required 24nm of torque received 48nm. Thus Saturday afternoon was spent running round local engineering firms to get the snapped bolt extracted. This mission failed, we would have to wait until Monday for the bolt removal. Disheartened, a new chain and sprockets, and some cables were added to the carcass of 'Cat.

Saturday evening was spent in the local where we got to see 'a little bit more' thanks to the hen party before retiring back to Cassa Del Stretchie. Where upon the evening ended with me lying on the floor, being straddled and covered in Baby Oil. In light of this fact I'm sure you, like me, will consider the weekend a complete success.

[lemmings999]

You win

; )

more like i lose :(

[lemmings999]

Where upon the evening ended with me lying on the floor, being straddled and covered in Baby Oil. In light of this fact I'm sure you, like me, will consider the weekend a complete success.

Stretchie
, you didnt? did you:pukel:

[Beckett]

A good laugh was had on the sunday as well :) and double checking of torque values before leaving stretchie loose on things again....

[squirrel_hunter]

Sometimes, some days are best spent in bed.

So after the weekend the engine was taken to Piston Broke to have the offending bolt removed and the assembly could continue. But it didn't last long, another bolt was snapped this time in the clutch basket so back to Piston Broke it went. And thus everything was assembled up to the Cams on Thursday night where I appeared to 'help' finish the build, get the engine back in the bike and get Strechie and GG of to the Lakes.

With much trepidation assembly continued on the Cams and covers, torque was delegated to me as Strechie could not bear to break another bolt. And he didn't. I did. I here by publicly tender my apology for snapping a clutch spring bolt. I make no excuses (other then although the manual said 8nm, the wrench only goes to 10nm; I had already done 5 of the 6; The bolts look piddly; They really should have been able to cope with more) for my actions.

So with the engine assembled around midnight and after a marvelous curry the engine advanced to the garage to meet its frame. The plan: get the engine in the frame that night, get the bolt out in the morning, get the rest assembled and get riding...

We then hit the next problem. The chain. The previous chain and sprockets needed replacement, and after last weekend and the first bolt snapping eager to achieve something the new chain was riveted in place. Now we all know the the chain pivots around the swing arm and thus the frame, which this chain did. Unfortunately we also decided to pivot it round the lower frame spar. On discovering this we went to bed via alcohol.

Well the morning gave us 4 tasks: Get a new split link and rerivit the chain, get the broken bolt out of the clutch basket, get a new bolt, get the engine in, get everything back together, and get going. But events conspired against us, Piston Broke were closed so the bolt remained in situ and Fowlers didn't have a spare split link. Game over.

Mac99 popped in to help load the engine in the frame ready for the week of work to come and Strechie and GG left for the Motherland in the cage. The saga continues...

[lemmings999]

Sometimes, some days are best spent in bed.


once again " stretchie, you didnt, did you"

[anna]

oh dear god!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!

[valleyboy]

where ? !

[_Stretchie_]

once again " stretchie, you didnt, did you"

OH I DID!!!!

Lots of working away and being away for the weekends later and I am ready to start working on the bike again. I got the engine mostly plumbed in and the carbs back on (BLOODY CARB COLLAR BOLT'S A RIGHT FIDDLY BUGGER - Mac and Squirrel know which one I mean).

HOPEFULLY, all that's left to do is fit the downpipes, add the airbox, finish plumbing the engine in, just a coule of wires and the earth left to do, fuel tank on, battery in, fill up oil and coolant and try to start her up.

If this works fairing back on and off I pop to start breaking it in again

Fingers crossed :smt023


**EDIT** Oh and fit the chain again DUH!

[valleyboy]

I have carb balancing vacuum gagues if you want to borrow....