Jennifer's Makeover

[Flyboy]

Today was spent with one of these


And a tin of this


Dressing valve seats and making sure nothing leaks.







Before and after


And one last one of nice shiny ports, just because I can..........


Next weekend will be a good clean to get rid of any left over grinding paste, and reassemble and paint.

[Matchless]

Stan, you are busy with the good part now! I am still amazed at the condition of that motor for its mileage! You must replace something at least!
How is the timing chain?

[chuck hahn]

I am calling your Home Owner Association Buddy!!!!!

[Flyboy]

You know, Andre, myself and Chris (Tatu) were having that very conversation a few days ago, and he is adamant that that I should replace the chain as well, as it is probably the weakest part of the engine, and I understand his concern 100%, under normal circumstances I would, but that would mean splitting the cases, and I have sort if decided not to.
A you well know, the bottom end on these engines are bullet proof, and if the top is looking good, I realy feel that I will achieve nothing by splitting the cases, I will put folding money on the table that all is well down there, and I would just be introducing the possibility of oil leaks, at the moment she is bone dry, don't want to mess with it.
I will replace clutch and gear shifter seal and call it good, I think.

I am a betting man, so I will take a flyer on the cam chain being good for another few hundred thousand.
And like I said to Chris, in 30 years of riding GS motorcycles, I have only ever broken a cam chain once, on my GS850G, at stupid RPM, dragging my buddy on his GS1000G between the lights.

The original plan was to tear the engine down and replace all the bits, whether they needed it or not, expecting things to be way out of spec, and I mean, everything, rings, valve guides, valve seats, cam chain, even the gearbox, main and lay shaft bearings along with the pinion bearing.
Problem is, finances have dried up, and I really don't have the cash any more, part of the reason the build stood for six months, If I am ever going to get her finished and on the road, I have had to reassess the situation and do what needs doing and live with what is still usable, and that burns my arse like you have no idea, but so be it.
There are many bits which are "fine" but I want it perfect, like my headlight trim ring which has a couple of scratches on it, and my clocks which are ok, but not perfect.
Even running a hone through the bores and putting the rings back in does my head in something like you can not imagine, but is more than likely what will happen, seeing they are still well within spec.
One of my big nightmares is going to getting a new screen for the "S" fairing.

As to the longevity of the engine, besides a bullet proof design, mechanical sympathy and good maintenance, I guess, always changed oil and filter at 5000km regardless, always made sure the carbs were synced and not leaking, no rich or lean runs, air filter was washed every weekend, a little over the top, I know, but only takes 10 minutes and the results show.

Doing the valves yesterday, I could see there was a little valve regression into the head, but nothing major or to be concerned about, as you can see the seating surface is just below the centre of the valve seat, perhaps a millimetre or two, no big deal, and probably due to making sure my valve clearances were always good and in spec.

Chuck, never mind the body corporate, you may rather want to have a chat with my bank instead.

[Nessism]

Doing the valves yesterday, I could see there was a little valve regression into the head, but nothing major or to be concerned about, as you can see the seating surface is just below the centre of the valve seat, perhaps a millimetre or two, no big deal, and probably due to making sure my valve clearances were always good and in spec.

Did you check the seat width Stan? The spec is 1.1 - 1.3mm. When the valves recede into the head the seat widens. Not sure how much this matters though...

[Flyboy]

Ed, to be honest, no, I did not, I will be sure to check and write down few numbers on the weekend when I reassemble.

[rustybronco]

A question for you Stan. What range shim thickness was in Jennifer?

[Flyboy]

Not sure Dale, didn't check when I took them out, but will be sure to make a note of the shims this weekend when I reassemble and let you know.

[rustybronco]

The reason I asked, is to see if there was any valve seat regression. By looking at your images, I don't think there is much, if any. Just trying to verify it with numbers.

Looks good so far.

[Flyboy]

H Daniel, still flying, but very little, market is quiet and I am trying to work my way out of it, had enough of it now, so doing less and less.
Ya Swambo still loves me, can you believe that sh1t, miracles will never cease, trying to get her to run off with some rich guy, but no such luck.

That is what I thought Dale, ya, the seats look good and don't look visably recessed....too much, the numbers will tell.

[rustybronco]

From all that I'm seeing, she's a fine looking engine...

[rustybronco]

What's your timetable to start reassembling her look like?

I'm trying to figure when it's best to send out the bits you have accumulated. Seat pan is scheduled for painting the first of the week as I have 'paint booth' time available and have nothing on my plate after Friday so I can get after the wiring harness this weekend.

Time to look for another switch board after USPS lost your last package and If I don't forget, I'll contact Frank Z for another set of decals.

[Flyboy]

DAle, i am hoping to have the head assembled this weekend, then I need to scrub and clean the bottom end and get it ready for paint.
Need to order new small end circlips so I can put the pistons back on the rods, probably do that tomorrow, and get them next week sometime, so if I can get my hands on a ball hone I can get the barrels and head back on in the next 3 or 4 weekends, going to put the old rings back, as much as it drives me mad to do it, they are still far from service limit.
I did manage to track down 70mm Fiat Uno rings, but the ring thickness is not correct, the GS has a ring thickness of 1.1mm, the Uno ring is 1.5mm, so will give them a miss.
Afyer gettin the motor back in, i will tackle the brakes, so no rush Dale, plenty to do here before I will need the seat.

Got a bunch of work to do on the e30 as well and a Kirby vacuum cleaner restoration project as well, to fit in between.

[Tech73]

Stan, I was wondering about something and this seems to be a good place to ask it. I'm putting new rings on the pistons & cleaning the heads as well and putting new valve seals in. I've thought about taking the pistons out to clean them. If I do this do I need to buy new pins or can I reuse the old ones and do most of you plane the head when you do a top end rebuild?

[rustybronco]

going to put the old rings back, as much as it drives me mad to do it, they are still far from service limit.

Got a bunch of work to do on the e30 as well and a Kirby vacuum cleaner restoration project as well, to fit in between.

I don't recall if you measured your old rings for free end gap?