fastbob Posted September 12, 2018 Author Share Posted September 12, 2018 (edited) How do you hold the gasket paper in place while you are profiling it? I’ve been looking at the price of some of the Gaskets I need for the Trophy and it’s made my wallet quiver. Not quite sure what you mean but anyway, what I do first is place the cover on the paper and draw round it with a fine biro . Then I take it off and scribble all over the jointing face with a marker pen several times and while its still sticky I put it back onto the paper using the drawn outline as a guide . This should make a print of the inner shape . Then , with the cover still in place,I use a bit plastic tube dipped in paint to mark all the hole positions. Next I punch out all the holes using a sharpened locator dowel . Lastly I carefully cut the whole thing out with a scalpel . If the gasket has all straight edges I skip the printing stage and just use a ruler to draw the inner shape and a bit of the old gasket to draw around the wavy bits where the holes go . I'm sure there are other ways of doing this but I just kind of made this up as I went along. Edited October 3, 2019 by fastbob Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 12, 2018 Author Share Posted September 12, 2018 After much fiddling about I got the pistons into the cylinder block . Not so easy with new rings and freshly honed bores . Quote Link to comment Share on other sites More sharing options...
Mickly Posted September 13, 2018 Share Posted September 13, 2018 How do you hold the gasket paper in place while you are profiling it? I’ve been looking at the price of some of the Gaskets I need for the Trophy and it’s made my wallet quiver. Not quite sure what you mean but anyway, what I do do first is place the cover on the paper and draw round it with a fine biro . Then I take it off and scribble all over the jointing face with a marker pen several times and while its still sticky I put it back onto the paper using the drawn outline as a guide . This should make a print of the inner shape . Then I use a bit plastic tube dipped in paint to mark all the hole positions. Next I punch out all the holes using a sharpened locator dowel . Lastly I carefully cut the whole thing out with a scalpel . If the gasket has all straight edges I skip the printing stage and just use a ruler to draw the inner shape and a bit of the old gasket to draw around the wavy bits where the holes go . I'm sure there are other ways of doing this but I just kind of made this up as I went along. Cheers Bob, I’ll give it a go when I’m ready - the best place to buy decent gasket paper is? Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 13, 2018 Author Share Posted September 13, 2018 How do you hold the gasket paper in place while you are profiling it? I’ve been looking at the price of some of the Gaskets I need for the Trophy and it’s made my wallet quiver. Not quite sure what you mean but anyway, what I do do first is place the cover on the paper and draw round it with a fine biro . Then I take it off and scribble all over the jointing face with a marker pen several times and while its still sticky I put it back onto the paper using the drawn outline as a guide . This should make a print of the inner shape . Then I use a bit plastic tube dipped in paint to mark all the hole positions. Next I punch out all the holes using a sharpened locator dowel . Lastly I carefully cut the whole thing out with a scalpel . If the gasket has all straight edges I skip the printing stage and just use a ruler to draw the inner shape and a bit of the old gasket to draw around the wavy bits where the holes go . I'm sure there are other ways of doing this but I just kind of made this up as I went along. Cheers Bob, I’ll give it a go when I’m ready - the best place to buy decent gasket paper is?I just buy it off eBay , its called Flexoid Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 14, 2018 Author Share Posted September 14, 2018 A small setback , one of the cam shaft journal bolts pulled the thread clean out before reaching the torque setting ( 12 inch pounds ) so I'm going to have to Helicoil it . Not a problem in itself but I wish it wasn't in such an important place . I think I'll fit a manual cam chain tensioner later on because the one in it seems to require a bit of "help" Quote Link to comment Share on other sites More sharing options...
megawatt Posted September 14, 2018 Share Posted September 14, 2018 I've replaced all the M7 rocker cover threads, in the cam caps, on my GSX race engine. Not a difficult job, but serious if it goes wrong. I'm sure you'll cope mate. Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 14, 2018 Author Share Posted September 14, 2018 I've replaced all the M7 rocker cover threads, in the cam caps, on my GSX race engine. Not a difficult job, but serious if it goes wrong. I'm sure you'll cope mate. Yeah, I know what you mean , I did all the M7 rocker cover threads in my previous GSXR 1100 L . Would you recommend a hand drill to enlarge the hole prior to tapping ? I can't remember what I did last time . By the way , I've just remembered what happened when I had the cam shafts out on that bike . Nearly every one of the bolts snapped when they were un screwed . In every case it was just under the bolt head so there was plenty of shaft remaining that screwed out with finger pressure . I reckon some heavy handed" mechanic " had used foot pounds instead of inch pounds ! Quote Link to comment Share on other sites More sharing options...
megawatt Posted September 14, 2018 Share Posted September 14, 2018 I just used the supplied tapping drill. Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 14, 2018 Author Share Posted September 14, 2018 I just used the supplied tapping drill. That's what I'm going to use but did you use an electric drill or a hand drill ? Quote Link to comment Share on other sites More sharing options...
megawatt Posted September 14, 2018 Share Posted September 14, 2018 Electric pillar drill and a hand held vice to make sure it was exactly 90 degrees. Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 15, 2018 Author Share Posted September 15, 2018 Electric pillar drill and a hand held vice to make sure it was exactly 90 degrees. Hmm, I don't have access to a pillar drill and I don't really want to take the head off again . I reckon I should be ok , after all I'm only enlarging an existing hole . Anyway, apart from this its finished. Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 15, 2018 Author Share Posted September 15, 2018 Well I might have spent a few quid on top of the original £50 but I think I've done alright. Some bike breakers are obviously a lot greedier than others. Look at this FFS ! Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 15, 2018 Author Share Posted September 15, 2018 Electric pillar drill and a hand held vice to make sure it was exactly 90 degrees. Ha ha ! What was I thinking, I don't need to drill it . My Helicoil kit just arrived and the drill just drops into the hole . Well it would wouldn't it if the old thread has pulled clean out ? So no need to drill at all . Happy days. Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 16, 2018 Author Share Posted September 16, 2018 We'll I did the thread repair and the bolt tightened to the prescribed 12 inch pounds but other bolt on the same cam cap gave way this time so I had to do that one as well . To remove the cap you have to remove three other cam cap bolts because of the upper chain guide. I know its not the end of the world if it goes wrong but this is nerve racking stuff , turning a little torque wrench and praying for the click Anyway all 16 bolt are now tightened to the correct torque , the tappets are set to optimum gap and I've bolted the lid on . Just waiting for some shiny new spark plugs and that's it . Quote Link to comment Share on other sites More sharing options...
Via Posted September 16, 2018 Share Posted September 16, 2018 Well I might have spent a few quid on top of the original £50 but I think I've done alright. Some bike breakers are obviously a lot greedier than others. Look at this FFS ! That is ridiculous! (And 4 times what I paid for my whole ER5 )Engine is looking sweet, good job Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 20, 2018 Author Share Posted September 20, 2018 (edited) When I swap engines I'm going to have to keep the old starter motor. As its been playing up recently I decided to buy some new carbon brushes and solder them in myself . I also gave the commutator a clean up with fine wet and dry . As you can see in the picture the old brushes were just about worn down to nothing . Service kits are available but this only cost me a fiver. Edited October 20, 2018 by fastbob Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 20, 2018 Author Share Posted September 20, 2018 I gave the outside of the starter motor a bit of a spruce up . Well I couldn't put a scabby starter on my posh engine could I ? Quote Link to comment Share on other sites More sharing options...
fastbob Posted September 29, 2018 Author Share Posted September 29, 2018 I'm waiting for my manual cam chain tensioner to arrive . I've ordered a British made one rather than one of those coloured ones from China. Quote Link to comment Share on other sites More sharing options...
fastbob Posted October 8, 2018 Author Share Posted October 8, 2018 My cam chain tensioner arrived , it looks very robust but the finishing could be better. The mounting bolts were ridiculously short with only about 4 revolutions of thread protruding so they got replaced. So that's it now , the very last piece of the jigsaw is in place . All that remains is to swap the two engines . I think I'll wait until after my Speed Awareness Course because I'm going to need transport over to Warwick. I'll resume this thread with a few before , after and during pictures. I'll have to move the cooker to get it through my kitchen and into the lounge first . Quote Link to comment Share on other sites More sharing options...
Via Posted October 8, 2018 Share Posted October 8, 2018 My cam chain tensioner arrived , it looks very robust but the finishing could be better. The mounting bolts were ridiculously short with only about 4 revolutions of thread protruding so they got replaced. So that's it now , the very last piece of the jigsaw is in place . All that remains is to swap the two engines . I think I'll wait until after my Speed Awareness Course because I'm going to need transport over to Warwick. I'll resume this thread with a few before , after and during pictures. I'll have to move the cooker to get it through my kitchen and into the lounge first . It's the wrong colour, you know you need to paint it now. Quote Link to comment Share on other sites More sharing options...
fastbob Posted October 8, 2018 Author Share Posted October 8, 2018 My cam chain tensioner arrived , it looks very robust but the finishing could be better. The mounting bolts were ridiculously short with only about 4 revolutions of thread protruding so they got replaced. So that's it now , the very last piece of the jigsaw is in place . All that remains is to swap the two engines . I think I'll wait until after my Speed Awareness Course because I'm going to need transport over to Warwick. I'll resume this thread with a few before , after and during pictures. I'll have to move the cooker to get it through my kitchen and into the lounge first . It's the wrong colour, you know you need to paint it now.Hmmm , yeah I suppose so , I could have had a red blue or black anodised one but I decided to buy British. I reckon I'll leave it as it is so it stands out rather than blends in. Usual question, how's the leg ? Bloody hell ! I've just had an email from the supplier offering to refund half the price ! All I did was make a few honest comments similar to those above . They even apologised for the silly instructions that said " Remove the old tensioner and throw it at your neighbours Harley etc " Sellers must be shit scared of negative feedback. Quote Link to comment Share on other sites More sharing options...
Hoggs Posted October 9, 2018 Share Posted October 9, 2018 ...best instructions ever Quote Link to comment Share on other sites More sharing options...
fastbob Posted October 9, 2018 Author Share Posted October 9, 2018 Here are those instructions in full , check out the last bit . Quote Link to comment Share on other sites More sharing options...
Via Posted October 10, 2018 Share Posted October 10, 2018 Hmmm , yeah I suppose so , I could have had a red blue or black anodised one but I decided to buy British. I reckon I'll leave it as it is so it stands out rather than blends in. Usual question, how's the leg ? Bloody hell ! I've just had an email from the supplier offering to refund half the price ! All I did was make a few honest comments similar to those above . They even apologised for the silly instructions that said " Remove the old tensioner and throw it at your neighbours Harley etc " Sellers must be shit scared of negative feedback. Usual answer... Slowly healing, getting to stage I can see improvements now so all good, next question is how much longer will I get away with working from home Quote Link to comment Share on other sites More sharing options...
Stu Posted October 10, 2018 Share Posted October 10, 2018 Usual answer... Slowly healing, getting to stage I can see improvements now so all good, next question is how much longer will I get away with working from home And the grass? Quote Link to comment Share on other sites More sharing options...
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