What damage have I done?

[Calum]

I would get the cylinder honed against a new piston. You will need to have a new piston to hone against. I would let whoever is doing the honing buy the piston. Or ask them if it needs a rebore. If they say no then buy the same sized piston.

There is probably a few tools I missed off the list. A good set of spanners and screwdrivers. So nuts and bolts to replace the ones you use is not s bad should.

[Matt47]

OK cheers. So I guess first step is to take top end into a bike shop and let them sort that out if it needs work done. Then I know what size piston I need (if they don't do it).

New bolts sounds like a good idea too, hadn't thought of that!

[Calum]

Yeah, get it to a shop and ask if you will be fine with a hone. In my experience you don't tend to save much money by buying the piston yourself.

I mean sure, if you can get the piston cheaper then by all means. But the risk of buying the wrong one could outweigh the savings you might make.

[Matt47]

OK so not much progress since last post, but I have now at least removed engine from the frame...

Still not made it to a shop to check cylinder, but have ordered a flywheel puller and made up a holding tool for clutch/flywheel which I'm chuffed with!

All prepped and ready to operate after a good clean. B-)

[Calum]

Nice, keep us posted. Any problems throw up a thread.

[Matt47]

Well I finally got myself organised and have everything ready for the rebuild 7 months later! :-S

Crank has been rebuilt (not by me!), barrel/head skimmed, powervalve cleaned, got full seal kit and full Athena gasket kit ready to go... Now I just need to remember where everything goes. :-))

[Calum]

@Matt47 it's fairly straight forward but do shout if you need help.

[Matt47]

Ok, so my next silly question is... How do I remove seals the correct way to avoid damaging anything?!
Think I have read that you can use screws to give yourself something to pull on - is this correct? Not keen on digging them out with a flat-head (unless they pop out easily).

You can probably tell I'm a bit nervous about the whole thing, guess I need to man up haha!

[Calum]

@Matt47 I always had access to the seals from behind. Aka if they are the main bearing seals then removing the main bearings will give you access to them.

[Matt47]

Ah, makes sense thanks!

There was me thinking I had everything on my rebuild list, and I forgot to get the other bearings...

All remaining bearings seem to be in great shape, but I guess I need to weigh up whether or not to do a full rebuild without all new bearings. Is it worth the risk?!

[Calum]

@Matt47 What bearings need replacing?

The gearbox bearings cost 20 quid. It would be silly not to sort those out st that price.

If I were splitting the cases then I would just replace the bearings. But that's me.

[Matt47]

I only have the 2 main bearings for Crankshaft, and the top end stuff.

I'll have to commandeer the oven once my wife has gone to bed, and get them all out and have a proper look at them! They all feel/look in good nick but I might as well take them out anyway to make the seals easier to change.

[Calum]

As said, for their cost I'd do the gearbox bearings.

[Matt47]

Yeah I suppose so, especially after seeing the post on gearbox bearings (quarter of the price of what I can find in France - and that includes postage from UK).

Disappointed that I overlooked these when ordering, but it would annoy me more if I didn't do it right after it has sat in bits for 7 months plus!

Cheers for all your support mate, will hopefully get them ordered up soon.

[Calum]

Simplybearings yeah? Grab all th Koyo bearings

[Matt47]

Yeah, that's the one - amazing value once you know what to look for! €105 for 2 genuine Crank bearings or €28 for 2 koyo shielded (which were what mine were).

[Matt47]

Tonight I heated up the crankcase halves to remove the bearings, and got all out apart from the 2 in the picture.

http://i1377.photobucket.com/albums/ah75/MatthewT47/20150124_144844_zpsnakligp9.jpg

How do I go about getting these out, as they are only accessible from one side?

Cheers, Matt

ps. sorry about the date on pic lol,

[Calum]

@Matt47 i lay the crankcase faced down. With enough heat the bearing simply dropped out into the oven.

It was getting it back in which took a bit of skill.

[Matt47]

Ok cheers, will try again tonight. Obviously needs more cooking - gave it 30min at gas mark 1.

[Matt47]

So I tried again and no joy, then left it in almost an hour and the only thing that happened was I melted stuff unexpectedly... Guess i will have to take it somewhere to get it removed.
Meanwhile, does anyone know what this and the other needle rollers are so I can get them ordered from simplybearings?