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By Bullet thrasher
#1164
Hi all
Well I have Doris up in my flat. Stripped to the timing pinion and gudgeon pin. Really a bit miffed If I have to spend 50 odd quid on special tools? I can feel some roughness on rotation of the crank and it really does feel like mains on timing side. Should I replace both? My guess is yes. It looks like someone has attempted to remove timing pinion before as there are some scars on the boss above the seal. It's supposed to have only done 3000 miles and I don't really see any other evidence of previous bottom end strip.Piston is pretty close to 83mm, Is that standard? Looks like I have a Euro piston with the diagonal slot on the exhaust side. It's had an alloy barrel fitted so if i'm on standard bore I'll most likely go for a 535 high comp. More is more. Once I've figured out the last bits of strip should I remove distributor so I can heat cases and remove mains? Lots of questions, hope your up to answering them. I know a lot of this ground has been covered before but first Bullet strip for me. Also in a previous post I mentioned going for a 5 speed box and Norm mentioned the righ foo change kit from H's. I was just going to buy the the kit from them but is there a cheaper way? I'm also going for rear sets I think on reassembly. I'm not building a cafe racer but a sporty street bike.
enjoy the sun. Thanks
By Mark M
#17447
BT, what special tools? Oil pump worm can be removed by using a ground down 19mm spanner to get on flats, you might need the puller for the timing pinion if you can't improvise a puller. Apart from that, nothing required. Strip cases of all fittings that might be damaged by heat then pop into oven, heat up to 250 deg steadily over about 20 mins, then take out crankcase halves (best to do one at a time,) and tap smartly on a piece of wood to dislodge bearings. Have new bearings pre-cooled overnight in freezer and after re-heating cases to 250, they'll drop neatly into place. Have crank ready to use as a mandrel if you're worried about alignment. Get some welding gloves as this operation is HOT! Standard bore for a 500 is 84mm so it sounds like you've got a std bore. Don't know about Euro pistons, sorry!
REgards, Mark

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