Unfortunately, while working on the bike on this project, it became abundantly clear that my crank appears to have developed some free play. Like way too much free play. I will be testing the Voltage Regulator this afternoon, and then the motor will be coming out and coming back apart.

This was originally an unknown parts motor, so this is not completely out of the expectations. It appeared fine when I assembled the top end before Moab, but it seems that one or both of my bearings may have given up the ghost. Time to go spelunking . . .

So just an update to bump the thread for the new members (and to keep you old timers happy!) . . .

Finally go around to pulling the motor out of the bike this past weekend, and got it all torn apart. As a reminder, the motor had developed some slop in the main bearings, so all of the pretty work aside, the motor needed to come apart. Good opportunity to address the cranky transmission that did not like staying in gear in 4th and 5th.

The good news - the only problem with the transmission was the prior owner's failure to reinstall the cam stopper spring. For those less adept at names, it is the little spring behind the second 17mm bolt in the bottom of the motor, which is often mistaken for the oil drain plug. Apparently that happened here, and very well may be the reason the motor was set aside. Easy and inexpensive fix there!

The bad news - main bearings gone bad, and the rod bearing has enough slop to go ahead with a crank service while we are in here. Going to be cleaning up the engine outer cases while the work is going on. Not terribly expensive in the scheme of things. The motor has less than 500 miles on a fresh bore top end, and will be getting the electronic ignition detailed above reinstalled when it comes together. I also may test out the prototype ignition that I have on the way from Rex if I can find the time to do so.

All in all, this motor should be like a fine Seiko watch once it is reassembled, so the next enduroride, you an all expect a sunny visitor!

By the way - I have been so busy with website maintenance and work that I nearly forgot how much fun working on the bikes, chasing down errant NOS parts, etc, can be. I must get my life perspective in to better order!

My motor is now back with a completely rebuilt crankshaft, (full new rod kit) and new seals and main bearings. The shifter issue has also been fixed. The cases were bead blasted clean so are nice, raw aluminum.





My side covers on this bike had a lot of battle scars and discoloration. The choice was made (in part due to lack of interest in polishing them) to go with paint. Initially I was going with satin black, but decided at the paint store to try a cast iron look









Needless to say, this creates a second choice in that I need to decide whether to just clear coat the cleaned aluminum (to make keeping it clean a bit easier) or to go with the same cast iron color on the center cases. Anyone have an opinion ( )





Weigh in as I need to paint the center cases today if I am going that route . . .

If you keep the side covers cast iron look my vote is cast iron look all the way... just think it would look better.



.

So MarkT is the only vote and swings things.

I decided to go ahead with the matching center cases. A light clear over the paint will make it that much easier to keep the thing clean. This is Duplicolor Ceramic Engine paint so hopefully it will resist any leaks which my carbs are prone to . . .

Got the Clutch side cover installed and bolted down with the stainless socket heads.



And got the stator back in and the wire run through a new DEET grommet and ready to install in the bike.



I will wait for the flywheel, top end and everything else as it is a lot easier to manage the weight of what is on the stand than adding everything and shoehorning into a too small of space! I am liking the painted engine - will see how well it holds up.

Progress!




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Towels to keep errant piston clips topside!




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Cylinder on, head torqued, new Irridium plug & temp sensor in place!






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