ER5 Engine Swap / Build

This section is for discussion on old/classic motorbikes. Also please use this section to put your project and restoration threads.
Message
Author
fastbob
Posts: 4000
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): gsxr1100 wp and er5
Location: Coventry
Has Liked: 2189 times
Been Liked: 1663 times

Re: ER5 Engine Swap / Build

#91 Post by fastbob » Sun Oct 21, 2018 11:13 pm

Here we go then , after several hours of f*****g around with planks , levers , blocks and will power I finally got the engine bolts in . I thought I'd drag it indoors so I can gaze upon the fruits of my labour when the telly gets boring. Now all I have to do is stick the gubbins back on again. It seems such a shame to obscure the engine with pipes , the radiator and the tank . It kind of makes you understand where chop builders are coming from .
You do not have the required permissions to view the files attached to this post.
Last edited by fastbob on Sun Oct 21, 2018 11:24 pm, edited 1 time in total.

fastbob
Posts: 4000
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): gsxr1100 wp and er5
Location: Coventry
Has Liked: 2189 times
Been Liked: 1663 times

Re: ER5 Engine Swap / Build

#92 Post by fastbob » Sun Oct 21, 2018 11:20 pm

Via wrote:
Sun Oct 21, 2018 10:44 pm
fastbob wrote:
Sun Oct 21, 2018 3:44 pm
I've fixed it by fashioning a large , narrow washer from the lid of a lunch box. Took ages to do but it has done the trick. Strange . ( pic to follow )
I could have printed you one :thumb:
I'm sure you could but would it survive 100 ° + temperatures , water and vibration ? Thanks for the thought.

User avatar
Via
Posts: 1069
Joined: Tue Apr 19, 2016 6:35 pm
Gender: Male
Bike(s): Sinnis Max II / ER5
Location: Kent
Has Liked: 703 times
Been Liked: 512 times

Re: ER5 Engine Swap / Build

#93 Post by Via » Mon Oct 22, 2018 12:06 am

fastbob wrote:
Sun Oct 21, 2018 11:20 pm
Via wrote:
Sun Oct 21, 2018 10:44 pm
fastbob wrote:
Sun Oct 21, 2018 3:44 pm
I've fixed it by fashioning a large , narrow washer from the lid of a lunch box. Took ages to do but it has done the trick. Strange . ( pic to follow )
I could have printed you one :thumb:
I'm sure you could but would it survive 100 ° + temperatures , water and vibration ? Thanks for the thought.
Yes :lol:

Done a load of prints lately in PETG, incredibly strong, water resistant and easily survive past 100°c :thumb:

Prints I've done are for new hot end mount on the printer and parts are a few MM away from hot end which hits temperatures up to 280°c with no deformation.
Hoggs wrote:
Fri Jul 27, 2018 7:21 pm
I agree totally with @Slowlycatchymonkey

fastbob
Posts: 4000
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): gsxr1100 wp and er5
Location: Coventry
Has Liked: 2189 times
Been Liked: 1663 times

Re: ER5 Engine Swap / Build

#94 Post by fastbob » Tue Oct 23, 2018 12:05 am

Via wrote:
Mon Oct 22, 2018 12:06 am
fastbob wrote:
Sun Oct 21, 2018 11:20 pm
Via wrote:
Sun Oct 21, 2018 10:44 pm


I could have printed you one :thumb:
I'm sure you could but would it survive 100 ° + temperatures , water and vibration ? Thanks for the thought.
Yes :lol:

Done a load of prints lately in PETG, incredibly strong, water resistant and easily survive past 100°c :thumb:

Prints I've done are for new hot end mount on the printer and parts are a few MM away from hot end which hits temperatures up to 280°c with no deformation.
Ok, if you're up to it you could hobble out to your own er5 and have a look so no need to send dimensions unless you prefer . I wouldn't be surprised if your own thermostat is rattling around as well. Here's a pic of the ring I made to fill the gap and hold it in place . As you can see, I had to remove a little bit to keep the bypass hole clear but I could have just made it thinner . If your thermostat is dead level with the top of the housing its ok but mine sunk down about 1.5 mm over time . See what you think .
You do not have the required permissions to view the files attached to this post.

fastbob
Posts: 4000
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): gsxr1100 wp and er5
Location: Coventry
Has Liked: 2189 times
Been Liked: 1663 times

Re: ER5 Engine Swap / Build

#95 Post by fastbob » Thu Oct 25, 2018 8:23 pm

Everything bolted up , just needs water , oil , and petrol and its press start to go . I can't pretend I'm not shitting myself. It will be a lot of work and money down the pan if it goes bang 🤞🏻🤞🏻🤞🏻🤞🏻🤞🏻
You do not have the required permissions to view the files attached to this post.

User avatar
Speedy23
Posts: 1619
Joined: Wed Oct 25, 2017 9:33 pm
Gender: Male
Bike(s): Yamaha FJR 1300A
Location: nr Shipston on Stour, Warwickshire
Has Liked: 190 times
Been Liked: 572 times

Re: ER5 Engine Swap / Build

#96 Post by Speedy23 » Thu Oct 25, 2018 8:59 pm

....As my Yorkshire Mrs. would say......"it'll be reet...."! :thumb:
Oh my God, what's happened? I don't know man...I just got here myself!

User avatar
Tiggie
Posts: 2302
Joined: Mon Oct 10, 2011 7:46 am
Gender: Male
Bike(s): Nothing :-(
Location: Bingley, West Yorkshire
Has Liked: 238 times
Been Liked: 336 times

Re: ER5 Engine Swap / Build

#97 Post by Tiggie » Thu Oct 25, 2018 9:01 pm

as my Yorkshire wallet says " triple check everything first!!!' :lol:
I'm an idiot who puts up Christmas lights in November

User avatar
Stu
Site Admin
Posts: 32453
Joined: Sun Jan 07, 2007 11:03 pm
Gender: Male
Bike(s): FJR1300 BMW F650ST
Location: hull
Has Liked: 2793 times
Been Liked: 2433 times

Re: ER5 Engine Swap / Build

#98 Post by Stu » Thu Oct 25, 2018 9:06 pm

fastbob wrote:
Thu Oct 25, 2018 8:23 pm
It will be a lot of work and money down the pan if it goes bang
Not entirely true!

if it doesn't go bang it will be all for nothing :lol: :lol:

I'm sure it will be all OK :thumb:

I'm guessing you have turned it over by hand first?
Don't steal!.... the government hates competition!!!

fastbob
Posts: 4000
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): gsxr1100 wp and er5
Location: Coventry
Has Liked: 2189 times
Been Liked: 1663 times

Re: ER5 Engine Swap / Build

#99 Post by fastbob » Thu Oct 25, 2018 10:12 pm

Oh yes , I've turned it over by hand a lot .

User avatar
megawatt
Posts: 4763
Joined: Mon Jan 31, 2011 6:09 pm
Gender: Male
Bike(s): Fazer 1000, GSX1100ET
Location: Hastings, East Sussex
Has Liked: 726 times
Been Liked: 537 times

Re: ER5 Engine Swap / Build

#100 Post by megawatt » Thu Oct 25, 2018 11:01 pm

Why would it go bang? If you've built it properly and checked everything, just start it, listen to it for a while. Let it get hot, let it cool, then drop oil and water for some checks. Refill, then take it for a spin.
Bike work, I come to you and you can learn to do it yourself click the link below for more info
http://themotorbikeforum.co.uk/viewtopi ... 5&p=949652

fastbob
Posts: 4000
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): gsxr1100 wp and er5
Location: Coventry
Has Liked: 2189 times
Been Liked: 1663 times

Re: ER5 Engine Swap / Build

#101 Post by fastbob » Fri Oct 26, 2018 6:33 pm

megawatt wrote:
Thu Oct 25, 2018 11:01 pm
Why would it go bang? If you've built it properly and checked everything, just start it, listen to it for a while. Let it get hot, let it cool, then drop oil and water for some checks. Refill, then take it for a spin.
I know, its just a figure of speech but its still a nervous moment when you fire something up for the first time after a build. Let's call it excitement instead. I think I'll put in some Wilkinson's 10w40 for the first few miles and then some decent stuff after that . Thanks for the advice.

User avatar
megawatt
Posts: 4763
Joined: Mon Jan 31, 2011 6:09 pm
Gender: Male
Bike(s): Fazer 1000, GSX1100ET
Location: Hastings, East Sussex
Has Liked: 726 times
Been Liked: 537 times

Re: ER5 Engine Swap / Build

#102 Post by megawatt » Fri Oct 26, 2018 9:04 pm

You'll be grinning from ear to ear. Put good oil in it. Try to prime the cams and crank by spinning the oil pump over first. I used a rubber wheel on a drill arbor to spin mine over, or just oil everything before starting.
Bike work, I come to you and you can learn to do it yourself click the link below for more info
http://themotorbikeforum.co.uk/viewtopi ... 5&p=949652

fastbob
Posts: 4000
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): gsxr1100 wp and er5
Location: Coventry
Has Liked: 2189 times
Been Liked: 1663 times

Re: ER5 Engine Swap / Build

#103 Post by fastbob » Mon Oct 29, 2018 8:21 pm

Still haven't fired it up yet , I've put the coolant in and I've got Friday off so as long as it isn't pissing down I'll give it a go then .

fastbob
Posts: 4000
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): gsxr1100 wp and er5
Location: Coventry
Has Liked: 2189 times
Been Liked: 1663 times

Re: ER5 Engine Swap / Build

#104 Post by fastbob » Wed Nov 07, 2018 11:40 pm

I've put the oil in now but I still haven't started it yet . Instead I have smartened a few things up a bit while I've still got it indoors. I fitted a second hand under tray that was in better nick than what was on it . It came with a good set of indicators which was handy because mine were flopping around and , as I discovered, full of water . I also snipped out any old wiring bodges and did everything properly with solder and heat shrink tubing. I want everything super reliable because I might be going to the outer Hebrides on it next summer.

User avatar
linuxrob
Posts: 48
Joined: Sun Nov 19, 2017 4:04 pm
Gender: Male
Bike(s): Suzuki GSF1200S Bandit, GS125. Z500 from new
Location: North East UK
Has Liked: 29 times
Been Liked: 37 times

Re: ER5 Engine Swap / Build

#105 Post by linuxrob » Thu Nov 08, 2018 4:53 pm

Good fortune for tomorrows weather Bob.

Hope to pop out to the garage myself tomorrow (Friday) find my old zinc anodes and pick up some fresh white vinegar / Epson salts with shopping and try some plating. this time i have plenty of old phone chargers.

Rob B