T140 Tracker Style Build.
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A bit more progress has been made! I broke up for Christmas on Thursday, so on Friday morning armed with a mug of tea I retired to the garage to start on the engine.
The barrels came of nicely and the bores are in great shape and still on standard. i am hoping a light hone and new rings will do the trick.
And the cases came apart ok.
continued,
The barrels came of nicely and the bores are in great shape and still on standard. i am hoping a light hone and new rings will do the trick.
And the cases came apart ok.
continued,
Next was the task of removing 40 yrs of oil and crud from the casings! My favourite job!
I cleaned them first with paraffin and various small brushes, then cleaned them with brake and clutch cleaner to get rid of the paraffin residue. I think they came out pretty good.
continued,
I cleaned them first with paraffin and various small brushes, then cleaned them with brake and clutch cleaner to get rid of the paraffin residue. I think they came out pretty good.
continued,
Next it was onto the crank, removed the rods and the drive side main bearing,
No one has been in here since it was new!
then removed the sludge trap plug.
The sludge trap was not playing ball, so I had to make a puller to get it out.
continued,
No one has been in here since it was new!
then removed the sludge trap plug.
The sludge trap was not playing ball, so I had to make a puller to get it out.
continued,
The sludge trap was about 1/3 full. (The engine has done 18,000 miles confirmed by the MOT certs).
After thoroughly cleaning the crank, refitted the sludge trap with a new plug, loctited and punched.
Crank journals were standard and in spec, so re-fitted the rods with new shells, rod bolts and nuts, and fitted a new drive side main bearing.
I then removed the drive side bearing race and fitted the new one. I also replaced the timing side main bearing.
I am really pleased with the condition of the innards, and only really replaced the mains and shells because I had it opened up. The gearbox is spotless with no signs of wear. here is the gearbox pics as they came out before they were cleaned.
That's all for now folks, Merry Christmas and a Happy New Year!
After thoroughly cleaning the crank, refitted the sludge trap with a new plug, loctited and punched.
Crank journals were standard and in spec, so re-fitted the rods with new shells, rod bolts and nuts, and fitted a new drive side main bearing.
I then removed the drive side bearing race and fitted the new one. I also replaced the timing side main bearing.
I am really pleased with the condition of the innards, and only really replaced the mains and shells because I had it opened up. The gearbox is spotless with no signs of wear. here is the gearbox pics as they came out before they were cleaned.
That's all for now folks, Merry Christmas and a Happy New Year!
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Great progress 
Also great that the engine is in such good condition.
Also great that the engine is in such good condition.
Thats realy starting to come together now Steve and looking very tidy , for a bike that spent all that time standing its in good shape inside with not a lot of wear .
I love those home made bearing pullers there brilliant and save loads of time !.... a big from me .
I love those home made bearing pullers there brilliant and save loads of time !.... a big
from me .
Oldboy
Well-Known Member
I made a similar puller for the wrist pins by grinding down the head of a 3/8"x6" carriage bolt and used an old deep well socket large enough for the wrist pins to fit inside. Some experimenting on the old damaged pistons though, as the socket contacted the ring grooves. I can post a shot of the finished product in action later. Usually picture is worth a thousand words, but in my case it's worth a whole dictionary and a set of the World Book Encyclopedias.
Nice RD400 in the background, with expansion chambers on no doubt ??.
What better way to spend Christmas than in the garage playing with your toys. Bet you're not cold with that heater on either.
What better way to spend Christmas than in the garage playing with your toys. Bet you're not cold with that heater on either.
How did you guess it would have expansion chambers on it? Am I that obvious!
I had to turn the heater off eventually, I got a bit too close an nearly scorched legs!
Here's the RD400, 40 yrs old and goes like a good un!
That Ring-Ding is a beaut.
Surprising to see such clean con rod top ends, they are almost always toasty brown with baked on oil.
Everything internally looks non-typically clean, external filth is a given. I did notice one small chip on the piston skirt, (right side piston in the photo); shouldn't hurt anything.
You did install the sludge trap plug just flush with the crank cheek face, correct?
Excellent work, and nice special tools.
Surprising to see such clean con rod top ends, they are almost always toasty brown with baked on oil.
Everything internally looks non-typically clean, external filth is a given. I did notice one small chip on the piston skirt, (right side piston in the photo); shouldn't hurt anything.
You did install the sludge trap plug just flush with the crank cheek face, correct?
Excellent work, and nice special tools.
Hi GP, I was pretty amazed at the condition of the internals considering it has not run for 25yrs!
I just went and checked my pistons, and the bit that looked like a chip was just oil and wiped off.
I fitted a new sludge trap plug. I measured it's thickness and compared it with the thread depth and oil way in the crank, and when the plug was flush it was 1/8" away from the oil way.
Oldboy
Well-Known Member
Haven't some this year but I think Stan Shenton's book mentioned removing the sludge trap completely and reinstalling the plug because it can trap so much sludge that it can block oil to the rod bearings. I never thought it was a good idea to use anything that could cause blockage to any part of the oiling system.
Any thoughts on this?
Any thoughts on this?
Re-install an undamaged original trap, or install a new one. Bare trap in the crank doesn't work the same without the inner tube.
That is correct.
Nice tools and that cleanliness of the inside of the cases is a +. Keep those pictures coming.
I recognised the end can. They were all the rage when the RD's and GT's were about, sounded good too.How did you guess it would have expansion chambers on it? Am I that obvious!
I had to turn the heater off eventually, I got a bit too close an nearly scorched legs!
Here's the RD400, 40 yrs old and goes like a good un!
This makes me realise I'm getting old
Here's my old GT 250, and later on with an awful fairing on it ready to tour the Lake District.
No expansion chambers as you can see. Always liked the RD's, But Barry Sheene played a big part in me buying a Suzuki. Have a great Christmas day in the garage
. Oh and do keep warm.
It has been a long time since I was on the forum, so I thought I better update the thread!
The project has been a bit stop start to be honest. I started a new job in January, lost my Dad in February, and since then Mum has had 2 falls resulting in 4 broken ribs the first time, and a dislocated shoulder the second time! So most free time has been helping Mum.
After a light hone of the bores, there were some scores that were a bit deep so ended up having a +20 thou rebore.
Then it was time to get the engine back in the frame complete with a new 'heart', Morgo oil pump.
Then it was time for more polishing.
continued..............
The project has been a bit stop start to be honest. I started a new job in January, lost my Dad in February, and since then Mum has had 2 falls resulting in 4 broken ribs the first time, and a dislocated shoulder the second time! So most free time has been helping Mum.
After a light hone of the bores, there were some scores that were a bit deep so ended up having a +20 thou rebore.
Then it was time to get the engine back in the frame complete with a new 'heart', Morgo oil pump.
Then it was time for more polishing.
continued..............
Nice progress! Hope your Mum is doing better.
