Bikemonkey's NC30

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CMSMJ1
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Bike owned: NC30-No9, NC27
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Re: Bikemonkey's NC30

Post by CMSMJ1 » Thu Jun 28, 2018 11:30 pm

Great work dude. if and when I can get the time adn space to do the same, I'll be following you. I suspect the gear selector on mine is fucked.

Handy that you've been doing it all adn taking nice pics. I will be wanting to clean pistons, lap valves, deburr the ports and generally sort it out. not going to happen soon though
IMPERATOR REX ANGLORUM

The V4 is the law..

NC30 - No9 > My old mate
2005 ZX10 C1H - It is a beast
KTM Duke 390 - for shits and giggles

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bikemonkey
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Bike owned: 92 NC30, 90 VFR750
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Re: Bikemonkey's NC30

Post by bikemonkey » Tue Jul 10, 2018 9:51 pm

Progress!

Last week I prepped the engine for rebuild, removing all the old gasket and cleaning the mating faces. That was boring and time consuming, I didn't take any pictures surprisingly.

Today my new (used) gearbox turned up, and after swapping over a bearing and a couple of thrust washers it was ready to go into the engine.

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But first I changed the selector forks for the ones I had lying around as they were in near new condition apart from a slight bit of surface rust. Installed the selector drum and gave it all a healthy coat of oil.

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Then I put the gearbox into the engine, coating it with a good amount of oil, especially the bearings. New output shaft seal and clutch rod seal fitted. Input shaft bearing plate torqued and gears set to neutral to test freedom of movement.

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After that I applied a good coating of oil on all the crankshaft bearings and any area that had had it wiped off. Before applying the gasket sealant (threebond) I cleaned all the mating faces with brake cleaner to ensure a good seal. You really don't need a lot of this stuff, so smeared it thinly with my finger removing any excess. And I still think I put too much on!

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Getting the lower crankcase on was a pain solely due to the selector forks not playing ball, but I got there. 10x 12mm bolts fitted first and incrementally torqued to spec. Then 7x 10mm bolts fitted and incrementally torqued. After those I got the upper bolts in and torqued, which was a massive faff with the two bolts I had to leave fitted, but I got to them eventually.

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As you can see above one bolt is missing (bottom left). This bugger snapped on me before the torque wrench clicked. Luckily when I removed it it came out whole. PHEW! :oops:

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I'm guessing either some oil was in the female thread and threw the torque figure out, or the bolt was simply past it's best and let go.

Either way I have ordered a new one and can still get on with the rest of the rebuild this week :peace:

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NGneer
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Re: Bikemonkey's NC30

Post by NGneer » Wed Jul 11, 2018 1:06 pm

Glad you managed to find a gearbox Oli - rebuild is looking good :-)

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bikemonkey
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Re: Bikemonkey's NC30

Post by bikemonkey » Thu Jul 12, 2018 12:06 pm

So last night I got loads more done on the engine, better alternative to the football in my opinion!

Started off with re-assembling this lot, coating everything in oil as I went.

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The sprung loaded assembly above has a plate that goes under/over it which was a pain to get on without things pinging everywhere, as such I forgot to take any more photos of that bit.

The case went back on with a new gasket and a new shaft seal :peace:

Oil pump was next, along with the pipe and relief valve.

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I used a thick piece of acrylic to jam the oil pump chain to be able to torque the sprocket bolt.

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Water pump got bolted on with a new seal.

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I left the clutch pack all together so it just slid back on nicely. Need to torque the nut up once I've fitted the engine, I'm not happy doing it on the bench without a proper engine stand or clutch holding tool.

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Primary drive gear, spacer and washer went into place with a little lining up with the clutch.

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Starter motor, starter gear and starter clutch all placed in. Got to torque the starter clutch bolt later too.

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I wondered how I'd know which pick-up went where, but there made so you literally can't mix them up!

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I put the clutch case on after that, without a gasket, just to keep everything in place when it gets lifted into the frame.

Generator was a doddle, just need to remember to torque that up too. Again case put on with no gasket.

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I fitted the sump cover properly with a new gasket as I won't be needing to go in there again.

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And fitted a new oil filter just to seal everything up.

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Just waiting on a new bolt to replace the snapped one. Whilst I'm waiting for that I'll clean up the frame and the bits on the engine I missed.

I'd do the valve clearances but I don't want to turn the engine without everything torqued up properly, so I'll just do them once it's in the frame. Not like I'll have much in the way anyway!

Once it's in I'll still have the wiring loom to finish before I can get it started anyway!

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jim157
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Re: Bikemonkey's NC30

Post by jim157 » Thu Jul 12, 2018 11:21 pm

You're doing a great job there mate.
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