SH2: The Rebuild (Image Heavy)

[squirrel_hunter]

Well last year I ran the engine out of oil again. Between then and now I learned to drive a car and stole Stretchie's Blackbird. But I need my SV back and at the moment I have plenty of time on my hands. So here is a rebuild thread to document my slow progress and hopefully prevent me from loosing another £50 bet.

Part 1; Dismantling:


Yes that is an oil drain try beneath the bike, oh the irony.


Prop the tank up to get to the air box.


Then remove it.


Drain the coolant.


Disconnect the carbs.


And remove them.


Take the clutch drive, the gear leaver, and the chain off (Its easier to remove the rear wheel or slacken it off to get the chain over the sprocket).


Remove the radiator.


Take the exhaust off, the rear cylinder collar was rusted nicely.


Disconnect the electrics.


Then drop the engine out.


Leaving a lonely engine on the floor.

[mattSV]

Your downpipe needs a polish

[squirrel_hunter]

Part 2; Getting Into The Engine:


With the engine on the workbench, we can begin.


Starting at the front and then replicating at the rear, take the valve covers off.


Exposing the camshaft holders.


Removing them to get to the cams.


Cams out, the valve head comes off.


As does the cylinder.


So we can see the piston.


Remove the piston noting the wear to the pin.


Take the clutch out.


And find its in pieces.


Take the oil pump off and the generator from the other side and the associated gears from the crank.


Leaving the cases ready to be split.


Separate the cases showing the gear box.


And the crank.

[squirrel_hunter]

Originally Posted by mattSV

Your downpipe needs a polish

Fancy giving it a go?



It will most likely go back on looking very similar...

[squirrel_hunter]

Part 3; Cleaning Up The Mess:

I didn't find that much metal floating around the engine cases. Which did make me wonder. So I cleaned the little that was there up. That is until I removed the oil filter that is at the bottom of the case in the picture below.



This is where most of my crank ended up as can be seen below.



I've had to do the cleaning up a few times as the engine as sent a bit of time traveling up and down the M4 over the past few months. But it is sitting covered up in the garage at the moment awaiting reassembly.

[Bluepete]

Jeez! Glad you know what you're doing. That's so far beyond what I could do. Good on yer!

Pete

[_Stretchie_]

Originally Posted by Bluepete

Jeez! Glad you know what you're doing

He was meant to be bleeding the brakes

[squirrel_hunter]

Part 4; Piston Broke? Yeah Thats Me:

Well the crank and the barrels went to Piston Broke Engineering, Bristol (0117) 9412300 for a regrind and a bore. The crank came back with bearings from a Ford Scimitar and a pair of cylinders ready to take the new pistons.

Trouble is this is where I lost motivation for a couple of months. Upon regaining the desire to get SH2 back up and running I found that I had mislaid the crank shaft thrust washer. So off to Piston Broke went the engine to get measured for a new one. This took some time.

But once the washer arrived, my gopher was dispatched to retrieve the engine. He did and then dropped it. Back it went to have a new main bearing as the cam chain gear on the crank had left a couple of nice dents it.

This time when the gopher picked it up he didn't drop it and brought it back to me with an extra bit. If anyone can identify what it is I'd appreciate it as I'm fairly confident its not from my engine so will take it back to Piston Broke once I know for sure.

[maviczap]

Better than reading a Haynes manual, in colour too

[yorkie_chris]

That actually looks like a fitting for braided brake hose, you got a pic in focus?