I suspect that some of you may be growing tired of viewing posts of my engine rebuild. I admit that it has been consuming much of the garage time, and space. However the end is in sight and the engine reassembly process is under way. Reassembly is always the best part of the job because by now all the dirty work has been done, parts have been sourced and inspected, and the time consuming process of coating and polishing has been completed. This is the point were I get to see the previous efforts pay off.
The disappointing part of it all is that the satisfying rebuild is rather short lived. These motorcycle engines are not complicated nor do they have very many parts that make them tick. This is the part of the job that I wished would take a little more time thereby extending the enjoyment factor.
Anyway…I managed to get the case assembled with the transmission and crank in place. I had previously opted to get rid of the kick starter and solely rely on either the electric start or a push start. I left the entire kick starter shaft out of the case and therefore required a plug to take its place. My concern is that there would be too much oil splash through the empty kick starter hole that would cause an excess of oil to spill into the right side cover. I machined up a spool type looking plug that will act as an oil stop.
With the upper and lower case halves sealed I was able to work on the left and right sides. The clutch, oil pump, oil filter, primary drive, starter drive, clutch linkage, shifter linkage, and stator were all assembled. Running through all the gears by hand confirmed that with some transmission RPM the shifting should work smoothly.
So the bulk of this post is going to be recited by the pictures. The bottom end of the engine is complete and I will move onto the upper end. Hopefully things will go as smooth for the second half.