As you can see it was bloody horid, I don't think it was ever cleaned from brand new. It took me about 3 hours to get it ready pull down. That black up the front of the motor is a mixture of dirt and grease, in parts is was about one inch thick. Actually stripping the bike down was a rear labourous task, every nut and bolt was rusted solid and each one fought like hell not to be moved.

The engine stripdown

Need to replace the oil pump, better hope not, the pump is driven by a nylon gear, this gear is located BEHIND the right side second inner engine case. This means the clutch must also come off.

To remove the centre nuts from both the clutch basket and the rotar I used a rattle gun.
The rotar puller is a 27 x1 left hand fine thread, about $30.00 from a cycle accessory outlet.
Even with it I had the jam the rotar with a tool I had made up for another job and I had a friend here to hold the motor down while I operated the puller. Like I said everything fought me:-)

Check out the screws holding the stator on, what idiot would reuse such things.

Impact driver to the rescue, and in reality is was just the BASHING I had to give them that they came loose, there was nothing left for the driver to grip. I had to hit them that hard I was lucky I didn't break the case.

See gear clusters and shift drum, once everything else is out of the way this assembly can come out as is, in one lot, zip them up to keep together then it is an easy install later.

Plastic bags, your friend in the garage. I use them to keep dissambled parts in a common location for easy find later.

As you can see I took a number of picturs during the strip down, I don't have any exploded views of the engine and the pictures may help in the reassemble process although I will be pretty right with most of it. Note you cannot completely strip this motor with basic home tools. The left side crank bearing is a sort of a slip fit into the case, it is not really but the case can be removed with gently tapping. The right side is not so, a much tighter fit and needs to be pressed out. I took mine to Ron Russ for that little job and remove the bearings from the crank and split the crank for conrod inspection, of course I need to replace all:-). At least there are no hard to get bearings or seals, they should all be available from a good general bearing supplier, except possibly the bigend.

Thats all for this time, I need to locate a conrod kit before I can begin reassembly.
In the meantime I will blast cases and polish or paint.

Nov 23 08
Ok read last line above. Have now blasted all the cases, thanks to vjmc member Garry for the use of his blast facilities. Painted up the bits I wanted painted and polished the bits I wanted polished. Note the damage on alloy bits showing the hard life this bike has had. It adds that little bit of character I think. I am still hunting for a conrod kit so I may now move onto the frame. I have to set it up for rear-sets so some modification to be done before I can repaint.

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