A while since my last update, I got a bit sidetracked I'm afraid!
Since last time I have cleaned up the frame
And fitted the rear exhaust manifold.
Also this final piece of the puzzle showed up and got torqued in, without breaking this time!
Then this evening after being let down twice, I decided to fit the engine on my own. (I do not recommend doing it on your own!)
It was a massive faff involving a big jack, two ratchet straps, blocks of wood, strength, swearing and because of the heat plenty of sweating!
This is why I don't recommend fitting an engine on your own.....
I also bent the gear selector shaft.... Another thing to mess about replacing!
Without dropping the engine again the only way to free the chain was to remove the swingarm. Much quicker and easier
After that slight detour I torqued up the front sprocket, clutch nut and starter clutch nut.
And fitted the rest of the clutch gubbins back in.
Next was to torque the alternator rotor down. Now I had a massive moron moment here too (I blame the heat....). The thing wouldn't torque down despite me locking up the rear wheel with the engine in gear. It was also making a horrible noise when I tried to torque it up.
So off came the rotor, cleaned up the end of the crankshaft and taper on the rotor and put back on. Same thing.
Then the lightbulb moment came, swiftly followed by the acknowledgement of muppetry. The clutch had been slipping!
These little bikes don't put out 85NM of torque, so of course the clutch couldn't handle it! What an idiot I am.
Stuffing some thick rag inbetween the primary gear and clutch gear solved the issue and a lovely click came from the torque wrench. Phew.
Finally back on with the engine cases, new gasket for each and all bolts torqued to spec. (I really like the Teng 5-25NM torque wrench I bought for the rebuild).
So I'll be on the hunt for a new gear selector shaft I guess! And I reckon tomorrow will be time to try sort the wiring loom!