K3 - Engine rebuild w.i.p

[muzikill]

Ok so here is how it looks so far...
http://farm6.static.flickr.com/5029/5592823763_08c66dc657_z.jpg

Ive re-used the following circlip...
http://farm6.static.flickr.com/5062/5593430052_b4b4e95459_z.jpg

It wont pop off but it 'spins' round, will it be ok?


In the same area, i'm not 100% this part is the right way round, the notch in the teeth should give an indication but im not sure...
http://farm6.static.flickr.com/5069/5593430768_7e079ffaa9_z.jpg
Anyone got advice on this?

I fitted the clutch basket ... btw if anyone is going to replace the gears please make sure you check the threaded ends like i didn't and found out that the threaded end was probably dropped or hadn't been looked after whilst sitting around at the breakers!
http://farm6.static.flickr.com/5306/5592838873_7df2121674_z.jpg

As circled, this was a barsteward to get on and took a very careful person oiling the nut and slowly turning it with a set of grips and taking it back off to clean off the tiny bits of metal off so they dont fall into the clutch! - nightmare in case i cross threaded it :(

[muzikill]

Well.........

http://farm6.static.flickr.com/5104/5605023047_f0920626e1_z.jpg

Ok, so almost there (front timing done, 16 on the chain counted :) ). The rotor and left hand bolt aren't torqued yet, the reasons for this are i'm going to replace the external circlip on the water pump but i was sent the wrong circlips!. Once this is done i will put it into the garage to get them to torque it, i dont trust my cheapy torque wrench to do it right. Another thing is i put the rotor on and slotted it onto the woodruff key but the rotor bolt is getting really tough to tighten and the starter driven gear behind the rotor still has about 5mm of play in/out, in it. Im not sure if this is the way it should feel. (considering how tight it was using the special bolt to get it off in the first place i think it probably is due the rotor being 'wedged' back in). I'm crapping it in case i break the rotor bolt trying to get it back on. The rotor bolt doesn't look the strongest!

So further delay waiting for a circlip the size of a 5p piece!

Feedback always welcome!

[muzikill]

Timing done, turned it by hand a few times it it's sweet as!

http://farm6.static.flickr.com/5069/5613670285_5f583863d6_z.jpg

ive put the covers back on temp just now as the engine is going into the local garage to get the rotor & the left hand thread bolt torqued properly!

[muzikill]

Ok, so i got the engine back from the garage, rotor refitted. After 3rd time doing this myself with the engine teetering on the car jack i finally got all the bolts back in. Anyone who has done this themselves how did you get on? - especially making sure all the pipes were routed right and the rear exhaust intake pipe went over the swingarm without geting mushed.

http://farm6.static.flickr.com/5222/5681350822_848eea4b44_z.jpghttp://farm6.static.flickr.com/5069/5681350012_64b72ceebd_z.jpg

oh, yeah heres how the garage looks after collecting various tools, fluids, and generally it's now looking 'worked in'

http://farm6.static.flickr.com/5145/5680785887_ba22eb4d0c_z.jpg

[zadar]

I would replace that circlip for oil pump gear, it is stretched.

[muzikill]

I would replace that circlip for oil pump gear, it is stretched.

Done, and apologies for the late reply!

Here is how it looks as of today, got the exhaust and tank to put back on. Fill full of fluids and see how it fires up.

http://farm6.static.flickr.com/5229/5698540555_e8c2ab36db_z.jpg

[cloister]

Ok, so i got the engine back from the garage, rotor refitted.
Was there still a bit of play in the starter gear. I had already re-fitted and started mine just before I read your post. It started and ran fine but I'm wondering if I should refit the rotor.


After 3rd time doing this myself with the engine teetering on the car jack i finally got all the bolts back in. Anyone who has done this themselves how did you get on? - especially making sure all the pipes were routed right and the rear exhaust intake pipe went over the swingarm without geting mushed.

I enlisted both grown up sons, it was still a pain and when I was done I realised I'd trapped the wires from the alternator between the engine and swingarm. You get extra points for doing it on your own.

[muzikill]

there was still play in the rotor. it was fitted by cupar motorcycles and they said it was normal to have around 3mm of play on the driven gear behind the rotor that connects to the the starter motor.

[zadar]

Yes, it should have play.

[cloister]

Thanks for that, might actually get it back on the road soon.