Hitchcocks Forum

A 2004 500 bullet classic engine. When I bought this engine, it was a basket case and all the "open" crankcase studs had been removed and thrown in a box with all the rest of the bits removed from the bike (then left in an outhose under a pile of builders rubble by the looks of things). Last bullet engine I did was a fair bit older and had studs pretty much throughout. This one had a mix of studs and bolts and I've just been working out where to put them.



Couple of questions really. The first is, Should these crankcases have dowels fitted? Two of the stud holes have machined recesses which I would assume would take a dowel on a Japanese motor but I don't have any and I can't see any on the parts list. Bottom left and top right holes on the picture below, holes which take M8 hex bolts according to the parts list. There are two slightly "odd" studs (slightly larger OD than the thread diameter) which are a tighter fit that go in the holes just behind the barrel and directly below the crank, I seem to recall reading somewhere these are instead of dowels?








Second thing, do I need washers under the nuts? The nuts are all flange nuts and the bolts are all flange bolts. The parts book online lists washers with each one but it also lists both studs and bolts for each position (depending on engine number). There don't appear to have been anywhere near enough washers of an appropriate size in the box to go on all these fittings. Could have been lost but I do seem to have a full set of nuts. A few of the studs also had spring washers on them (in the box of bits) but I don't see spring washers listed anywhere for them on the parts list. The bottom, middle stud in particular had two spring washers with the nuts on either end. Perhaps someone has added these later?

Not sure if this helps, but Redditch cases had a couple of dowels, one at the bottom corner of the oil tank and the other at the top front of the barrel. The studs went right through the dowels. As for washers mine is probably different as its nearly 60 years old but all the studs had ordinary nuts and flat washers.

Thanks for the reply. I'd like to save a copy of that picture if it's ok with you? Interesting to compare the similarities and differences over 50-odd years.

the slightly "odd" studs as you call them, is what centers the two cassings.



the dowels ar not used anymore to center the cassings as they serve a double purpouse.



i find i always funny when i read of people saying that there cranck was 0.2mm out of line.

a crank that's only 0.050 out of line, you can not even get the cassings to close.

and not to close means there will remain an opening of at least 20mm between the cassings.

Yes, course it is

Ok to save the pic I mean.

No dowels but think x2 of your bolts will be tapered and aligh cases as you tighten up regards

Meant 'align' I asked same question when I rebuilt my engine from a box of bits few years back,'Norm' from oz came straight back with answer