Did you have problems getting the swing arm pivot bolt out? I'm tidying mine up at the mo and wanted to have the frame powder coated but can't for the life of me get the bastard out.

No mate it popped straight out , I've had the engine out a couple of times so I greased it liberally , also the flywheel came off with a few taps .
To be honest mate I've never had a stuck swing arm bolt & the only way I can see of getting it out is with a lump hammer and a smaller diameter piece of metal so you don't damage the threads , someone holding the bike would be a good idea .
Hope you get it sorted OK bud

Red neck crank & bearing removal . . .
No CRMs were harmed in the making of these photos

Nice use of timber
I'd like to see what you used to split the crankcase

andrew19 wrote:Nice use of timber
I'd like to see what you used to split the crankcase

"No crank cases were harmed in the stripping of this engine "
i carefully tapped them and eased them apart using areas around the rear engine / swing arm mout where if i was to score the ally it wasn't a problem as it didn't need to seal there but i didn't score it as i was careful .
One side of the crank cases (clutch side) always comes away easily leaving the crank in the other side , it's been a while about 13 years but i've had this engine apart a few times

getting there

A bit more done today , had to make a generator holding tool

That did the trick !
Building the clutch back up I decided the tab washer had seen better days so off to leisure trail for a new one & some coolant .
Found a few things out today like when you buy the aftermarket clutch steels you get one extra & the tab washer that holds the inner clutch basket on is s**t , as I torqued the nut up the washer spun with the nut bending the tabs , I didn't notice at first and put the cover on & it got jammed on the bent tab washer !
So bottom half of the engine is is about there , generator cover needs to go on , barrel needs and head need to be torqued down , I've sourced some new pipes for the 2 stroke oil pump and the car de-ice pipes .

Well got some more done yesterday and today even with a few hold ups , was hoping to fire it up but ran out of time , the garage is ditched !
Just needs gearbox oil , coolant and petrol , already checked for a spark & fingers crossed the gears are OK

Well had it running today , already knew the brakes were binding so they're next
http://vid185.photobucket.com/albums/x1 ... EO0005.mp4

Well that's another £160 spent on brake seals front & rear , chain slider , braided front hose , dot 4 and cheap aftermarket levers . Unfortunately one of the front caliper bolts & the bracket seem to be catching the disk :O

How long do you think it'll be until shes roadworthy? Looks like your not too far off

Sean

Rear brake , think I have a bent front disk but have 2 spares , may fit my other wheels so I can check the rims on these as I think the rear is corroded so that means bearings ,new pads & fit the chain slider so other than tidying it up which will be next year I'm aiming to get it mot'd in Feb

Cool, im hoping to have mine ready before christmas as well. id be interested to see some more pictures of yours when its finished, seeing as mine had the same paint scheme/graphics as yours once apon a time...

Sean

my rad scoop graphics are in a bad way , my look at getting some one to knock some up for me in the future

In the garage today to sort out the stuck caliper pin , managed to free the caliper but disaster struck trying to get the pin out !
Brand new vice I'd just fitted !

Now just need to drill the pin out , replace the pin & sort out the locating guide I snapped off a couple of weeks ago .

That's a good advert for a Clarke vice.

I've got one so will have to be careful with it.

Did you see my email re rear brake bracket?