Assumption is the mother of all **** ups

@%$^%*(&^%~@~@##' *&^$£$%*@: !!!

I've been replacing the selector forks in my Bimota for a while now. The engine was stripped and prepared and I found a donor engine for some of the parts and bought the rest new.

I've just spend two weekends stripping it, replacing the parts, rebuilding it and putting the bike back together.

I finally got it all back together and looking as good as new and had a coffee before firing it up.

It turns out that having got to the stage of firing the bike up, I took it off the paddock stand and tried to push it out of the garage.
...Somethings wrong!

Even with the clutch pulled in, the clutch wasn't disengaging. In gear, the bike was locked.

SO I pulled the newly gasketed clutch cover off and the clutch basket. All seemed well so kept on fiddling.

NOOOOOOOOO!

on rebuilding it, I replaced BOTH the final drive shaft AND the countershaft. The Pegaso (the donor engine) is a FIVE valve head and so has a different cam chain assembly.

So the counter shaft is 3mm SHORTER than the F650 engine!!!!!!

That means I've wasted 16 hours and all the new gaskets and I have to completely strip the whole thing and replace the original countershaft!

For the sake of 3mm!!!!!!!

I'm going to cry!
Carl

Make a new clutch pushrod 3mm longer.

Doh.

Stop the clock!

Bike stripped, engine out. Engine stripped. Gearbox replaced and engine rebuilt and back in the bike and it's 5.50pm

That was Epic! You've never seen spanners flying so fast!

4 hours for a complete strip and rebuild

And I'm Spent!

The problem was the shaft. It meant when the clutch basked was torqued down it jammed on the outer clutch basket.

I'll NEVER asssume parts are the same again!

Carl

[yorkie_chris]

Well done. Don't think I could do an SV in that time. RD400 easy though

That was good going. Weird how the two engines use different countershafts despite fundmentally being the same motor with different heads. That's BMWs for ya (yeah I know it's a Rotax engine)

Chris, my record for an RD400 engine out, complete strip and rebuild (installing new crank and swopping barrels for rebored ones/new pistons), engine back in was 3hrs 42 minutes from first putting a spanner on the bike to firing it up again.

[Bibio]

Originally Posted by Berlin

Stop the clock!

Bike stripped, engine out. Engine stripped. Gearbox replaced and engine rebuilt and back in the bike and it's 5.50pm

That was Epic! You've never seen spanners flying so fast!

4 hours for a complete strip and rebuild

And I'm Spent!

The problem was the shaft. It meant when the clutch basked was torqued down it jammed on the outer clutch basket.

I'll NEVER asssume parts are the same again!

Carl

well done that man ...

Glad you have got it sorted mate!!!