Snags, snags and more snags!

It’s never an easy road to the race track when you're preparing an older bike ...but for us, at the moment, it’s like going uphill too.

Snag number 1:

Getting the engine apart provided us with a few problems. First nightmare was getting the centre nut off the clutch. We had to put the engine back in the frame. Then Ritchie sat on the bike to stop it falling off the stand, while I turned the socket and breaker bar – assisted by a short length of scaffolding pole – to finally release it. It went like a gunshot; it was bloody tight.

So then it was back out with the engine again to split the crankcase.

Snag number 2:

We took all the bolts out as specified in the manual, but there’s always one that won’t shift. You could feel it wasn’t going to come out. Plenty of soaking with WD40 was applied, in the hope it would penetrate the thread, but it still wouldn't have it after 24 hours. We gave it few taps to try to shock it loose and then, by heating up the crankcase around the bolt, it started to move; only a quarter of a turn though. A bit more heat and a few more shock taps and it started to turn slowly again and then it sheared off. Damn!

With the cases apart, we could at least get the mole grips on the bolt to try and turn out what was left of it. Not a chance - that bolt was only coming out with a drill. It was a long process before finally cleaning out what was left with a tap.

Snag number 3:

Once the cases were apart we took the old shells out. They were badly scored. This engine had not been looked after! They oil-ways were full of crap; black awful crap. Under one of the shells we noticed a piece of shrapnel – a small metal splinter – had become embedded into the top half of the crankcase. You could feel it with your finger nail. We thought it was all over and we’d need a new pair of crankcase halves!

However, a quick trip to our local Race Shop for a second opinion reassured us that if we could file it flush with the curve, it shouldn’t be a problem.

With nothing to lose, we used a small, fine half round file and carefully took the raised metal part down to the level of the alloy …without touching the case; it was no place for a shaky hand.

Pleased to say it was total success.

Snag number 4:

The oil chain drive pump chain tensioner was cracked and needs to be replaced. After a search on the internet Ritchie discovered one - good old Ebay!

Snag number 5:

The American postal service informed us that the new pistons ordered for the over-bore have been lost in Miami!

What next?