The motor with Del Orto carb

Just a couple of photos of the engine and carb before it goes back into the frame.

Rear master cylinder bracket

When I was at Steve's last night with the engine a friend of his, Richard, was kind enough to give me a small piece of ally plate so I could fabricate the rear master cylinder bracket. Its a Brembo master cylinder and I would have liked to show the name off but it just wouldn't fit. It didn't have to be too elaborate and it only took the best part of an hour. As a short cut and to make it look "Pretty" I used some thick black vinyl to cover it.

Steve started on the engine at 17:30 last night, first thing he found was the clutch thrust washer behind the clutch was lifting the basket too high so the clutch lock tab had no spline to grip to, after sifting through a multitude of shims he managed to sort it. Next thing was the oil pump cog was impeding on the drive cog, again a small shim sorted that out. On the bottom of the left hand side casing is a threaded hole that you screw in a crankshaft stopper, Steve had been using this all night to hold the crank but when he put the capping bolt in it stripped the thread! Steve had to drill, tap and put a helicoil in, all this AND stopping all the swarf going into the engine. After about 40 minutes he managed to suceed.

The engine has landed!

That was the left hand side, (the clutch on the Rotax), done, next was the top end! This actually went on quite well but when he came to fit the cam pulley he noticed it was touching the casing behind, he read the manual and it said there should be a shim behind the pulley. Steve is very maticulous when it comes to engines and said there was not one there, so again a shim was found to sit behind the pulley, then when fitting the new timing belt he found it was a touch too long, with the tensioning adjuster at maximum the free play, (when the belt is pushed away from the guide), was over 10mm when it should a maximum of 6mm, Steve put the original belt back on. Steve then set up the tappet gaps and valve timing, which is way, way over my head! Steve tried to explain but my head was hurting....DOH. When Steve was bolting down the rocker covers one of the threads stripped, so yet again he had to drill, tap and insert a helicoil, however this was a blind hole so no worries about swarf. I asked Steve to fit one of the better flywheels, pick up and generator windings as the original was looking very second hand! And then at around 22:30 Steve said the words, "Thats it, its done!!"

I will be spending all my spare time in the garage now just to get this project finished, I have almost all the parts I need now so nothing can hold me back!!