RH ReHab

[Jonesy :-)]

No carby manifold clamps?, no problem! these wont come off. That rope is gunna hold em on real good


Not really,this is part of the process I had during a 4 hour epic battle to get the carby's into the manifolds which I think are near new and quite stiff.
Anyway, I'd get one side started, and tighten the hose clamp to hold it while I went to the opposite side to work the carbys in to manifold only to have the first hose clamped side pull out again, this went on for ages, during the process I used silicon spray in the hope of getting the carbys to slip in with ease, another desperate measure was cutting off the top airbox bracket as I was 1/2 convinced that was preventing carbies to fit.......Eventually i tied one started side like in pic to prevent it coming out while working the opposite side in, by now I was using a rubber mallet to bash the frellin carbys in while applying pressure with a spanish windlass, I thought about softening the rubber mainfolds up with a heat gun, but this was the same day Penrith had 47 deg C and in my shed it was 43 so I figured they were as soft and supple as they were ever going to be. 

[BrettS]

Oh shit yeah, or the new spoked bike. You might need a few friends to ride them all up.
Or you n Eddie can hire a truck.

[Jonesy :-)]

Yeah should be ready by then but I'm thinking of taking my old bike that I got back off chrisso a while back...........its next up on the operating table, decisions decisions?
I

[BrettS]

Looking good, will it make it to the Rally?

[steptoe]

forward steps are steps forward, even if a backward step is taken inbetween

[Jonesy :-)]

It's been a bit quiet round here lately so thought I'd do a bit of an up date on Re-Hab.
I've almost got a long motor now, just needs gear selector gizmos'put back on and alternator on the other side of motor to complete
and the out of service tag is to remind me to fill up the middle gearcase

As usual the Routine Hazards of things not going right on this build have reared there ugly head again. This time the bottom banjo bolt for the oil feed line to the head snapped at just a tad more than finger tight when a spanner was introduced, shit photo but closer inspection shows it was already cracked on one side, wether the last rebuilder was heavy handed or just fatigued over years of duty? who knows but not a lot meat around that oil hole. Luckily the ute load of spares came in handy with minimal disruption to the build.

Finding top dead centre and setting up the timing was pretty straight forward with dots on cams lining up spot on with cam cap indicators

and I eventually tracked down some brake pads on ebay pyramid parts part No: PP70 just for future reference if you've been duped like Hen and me with ferodo pads.

[steptoe]

I don,t recall having seen bevels on the inside of "our" rings, small edge on the outside to show the  top of ring is all I remember/ have seen

[Jonesy :-)]

Thanks for the offer Eddy, much appreciated
But its already back together, well cylinders are on anyway. I went with the as is set up based on I've seen this bike on the road and it went well and ran clean. If theirs trouble down the track its a quick job to do the top end, After all I was originally only going to fix the jumping into gear problem

[XSIIE]

Paul, do you need a set of standard pistons and rings. I have a few sets.

[Jonesy :-)]

G,day Errol
you might be onto something?
You or Steptoe might be able to confirm (between you 2 you've probly built more motors and more recently), but I noticed that all the 2nd or middle rings had a bevel on the inside top edge and It's been too long ago that I built 581 to remember if those rings had the bevel. Its still the original bore(s), all cylinders measured up at 71.57, limit is 71.6 mm. Also the top and middle rings seemed a tad too big, but then again I can't recall what 581's were like? maybe I've got 1st oversize rings on standard piston?
But all the rings were the same, it was just this ring groove that was different,
EDIT:
Build progress is cylinders have had a light hone to bring back the cross hatching
Dodgy rings and pistons have been re fitted and cylinder block back on.

[Eveready1100]

Paul, are the rings on the other pistons the standard thickness. Just thinking that someone might have got some oddball rings (Focus maybe) and went to machine the lands a bit wider to accommodate them if they were thicker but made an error on that piston so just slotted in an extra ring to fill the gap???

[Jonesy :-)]

Hen, i dont think theres a part on this bike where someone hasnt been before 

[hen]

do you think some one has been in before you that is strange about the oil ring  and then the spacer

[Jonesy :-)]

I was wondering why the right side foot peg hanger looked like it had been broken and  welded right where it is weakest, the hole for the brake lever pivot
maybe this is why?
when refitting the motor I ended up with a 5mm gap between the LH foot peg and frame. so a 5mm spacer went in to prevent any stresses when all the motor mounts were torqued up


And the little build of surprises came through with the goods again
while decoking the piston I found No:2 piston had 3 support rings for the oil ring what the!
And this is what I found

anyone come across this before?
All the pistons appear to be genuine but I cant be sure. They have "yamaha"  and  "2H7" embossed but no tuning fork

[Jonesy :-)]

Gunna run the black swirlys till the rubber runs out and in the meantime do the original gold swirlies up..........thats the plan anyway