The MaC22 project

Well, I got a chance to spend a few hours on the bike yesterday and made a bit of progress.

Here goes.....



Here is where I was at, the work bench was looking a little cluttered but thankfully it was time to start re-assembling some things.

Starting with the brake calipers.



I used the vice and a socket to push the brake pistons back in.



The rear pads still have a fair amount of meat on them so I didn't replace them.



I did buy new front pads as the old ones were thinning out.



Want my advice then buy a vice as a vice is nice and worth the price, so buy a vice now. OK gice.........I mean guys



One.





Two, three.



That got me a little more space.

I reconnected the swingarm applying some grease to the bearings and bolts. It's not the cleanest but I will polish it a little more when the bike is back together.





The pulse generator sits in behind the left hand engine cover, re-connecting this bought me a little more workbench space.



Behind the right hand engine cover sits the alternator, reconnecting this bought me more workbench space.



It truly is amazing that this complex device creates electricity when the flywheel? spins around it. I think it's friction? and magnetic forces or some shit (I understand how it works just not how to explain it).



I got a package



I ordered these parts from RB Imports in Carringbah on Wednesday about 3pm and they arrived Thursday about 11am, that's pretty quick service.

it's hard to come by parts at the moment due to the earthquakes in Japan but Geoff had them in stock.



For those of you (like me) who are not mechanics and want to learn how to install rings, pay attention.



Your rings will arrive like this.



And the order in which they should be installed is like this (starting at the bottom and working your way up).



The bottom ring which is your oil ring is made up of three rings which need to be installed like so.

You must install the squiggly ring first, It is the only way.



Then you install the two thinner rings EITHER side of the squiggly ring.

One.



Two.



The manual recommends 20mm gap between the joins in the thinner rings.

The oil ring is designed to remove any oil from the cylinder on the downward stroke of the piston.

Ring two is the thicker of the remaining two rings (compression ring?) it has a slight sham fer which must go the right way up. To make this easier there is a "RN" mark on the top or maybe it's "ROPNOP"





The final ring only has a single "R" or "ROP" mark.





Try to scatter the joins in your rings for maximum seal and compression, for best results have them at 120 degrees apart.



Repeat x 4



Use some oil on you finger to lube the cylinder then slip it in.....:-/.....



OOOOOHHHHHH yeah



Ok, I'll get my mind out of the gutter now, you will find four of these at the top of the cylinder.



They help you compress the rings (you will need to do one at a time) so you can push the piston in.

I used a small flat-head screwdriver and worked my way around the rings.



All done



Flip the crankcase and apply some grease or oil for the crankshaft. I used high temp grease but only a little. Just enough to keep it lubed until the oil can get in there.



Apply it on the crankshaft also.



Sit it in there and tighten the pistons to it. It's easier to do two at a time then rotate your crank and do the other two.





I then applied some gasket sealer to the crankcase staying away from these areas.



They are designed for oil flow.



Crankcase back together and now it's time to tighten the 24 bolts that hold it together (make sure you lock-tight the bolts).



NOTE: the bolts must be tightened in the correct sequence, I have attached a photo to show this.



Next re-install the oil pump sprocket and chain.



Sump with a new oil filter (thanks Mr Ballzy) was next.





Sump on.

Oil filter was next.







Flip the engine and there are three more bolts on the other side.



Crankcase complete.







That is it for now.

The next step (for those who read the MaC19 project) will involve the head, some blu-tak and a feeler guage.

Scrooge

Are you sure that the black ring goes the second one? I'm pretty sure that it has rectangular cross-section. Which according to manual should go to top. And the grey one has trapezoidal cross-section that should go to the middle slit.
At least when i was checking mine they were.

This is the part of the manual that shows it:



Please don't say that you are sure. Please, please, please.

OK, so I finally had some time to work on the bike over the weekend. We are trying to build a mental health building in 11 months atm which should take about 18 months plus we are renovating our house so we can sell it (I want a bigger shed) so spare time is few and far between.

I have had a couple of full retard moments while working on the bike which I will go through as we go.

Here is how we left it last time.



Pistons currently sitting at TDC, the "T" mark on the flywheel thing shows this.



A little bit of blu-tak so I can check valve to piston clearances later, this was a little trick tought to me by Mr Mootavic.



Head on.



gear train in.



IN and EX facing each other, you can have them facing opposite ways also, as long as they are level with the head it matters not.



This is the begining of my full retard moment, the cam holders are installed incorrectly, IN2 and EX2 are correct as they only go one way, the rest (i'm not sure why) IN1, EX1, IN3, EX3, IN4, EX4 should face one another NOT face in opposite directions. I couldn't find anything in the manual to show this but I did learn a $165 lesson.



I couldn't get the cams to turn over easily but I went ahead and checked the valve clearances anyway.



Then I removed the head again and ordered new cams thinking the old ones may have been bent due to the piston explosion.

Blu-tak in place and clearance fine.



New cams arrived.





Take two, full retard moment No.2, I re-installed the cam holders incorrectly once again, long story short Dad came over and realized what the problem was.

Here is how they should look.



Here is one of the cam holders, notice they are slightly larger on one side.



I didn't take photos for the rest of the day as I was extremely pissed off with myself and started rushing to put things back together full retard moment No.3, 4 and 5 followed, I snapped one of the cams, forgot to lock-tite once then I dropped a cam holder spacer through the spark plug hole. Then I stopped as I realized I was making far too many mistakes.

Two weeks later I started again, I'm not painting the rest of the engine I have decided as someone want to buy this bike and I would like to have it running ASAP.

Engine covers on.









Ready to install.



Installed.





That's it for the moment, I am fishing with Dad this weekend but am taking next Wednesday off to work on the bike and am hoping I can get it running then.

I noticed the sticker on the sub-frame and here is what this bike originaly looked like.



I had a guy walk up to me the other day while I was riding the MaC19, he handed me a business card and told me if I wanted to sell it to call him as he wanted it for his son. I told him if he wanted to give me $10k for it he could have it as that's about what i've spent on it

I did tell him about this bike and he is interested, hence why I'm putting it back together faster than I would have if I painted the engine. My mate Bob also wants this bike.........wait till I finish it fuck yas

Will update again soon.

Scrooge