Another angle. Carbon pancake:



Really zoomed in. Are these small bar-like marks on the top edge of the piston head normal?




3/4 view of the piston. Looks like some mechanic applied loads of gasket cement LOL



Bottom lip of the piston. Signs of grinding with the cylinder (I maybe wrong though. Will check it out in detail later on)

Analysing the piston from side. Got my finger prints on it as well LOL



Zooming in. Area near top of the piston. Looks like the piston was having tough time with the cylinder. Loads of grinding marks. Is this normal? I can't say anything about the piston/cylinder clearance right now as I haven't bought appropriate tools yet.



Some area in the middle:



Near the bottom of the piston. Vertical scratches are a bit understandable but what on earth are these horizontal brown lines?

Ok, so we've got some visitors as well:












Thank you Mr. Fly but i've got some work to do.... Moving on.....

The engine case screws, pretty "screwed" up !!! And the gunk and stuff. I don't know how on earth am I going to clean this engine

Alright, next we should check out the oil pump. I had to cut most of the pipes with a really sharp knife.



Zoom:



Deformed screws once again:



The condition of the screws is horrendous. You MUST buy an impact screw driver !!! Till now my trusty impact screw driver has opened up even the most rusty, soft and screwed up screws as shown below:

Okay, the oil pump is off:



Another angle:



Closeup. The amount of gunk in this engine is legendary. There has to be some sort of world record for this.

Oil pump closeup. Disassembling it is probably going to be a major challenge:

Oil pump body closeup:



Another pump shot:



Closeup. I have no idea what this green stuff is. But as I see there is still some pretty good oil left in there even after 10 years!




Oil pump from another angle. Gunk, rust and fungus. How to clean this up? Would be a total nightmare.



Zooming in a bit:

Even more oil pump shots. (And no, oil pump is NOT my favourite component ). Check the amount of fungus on the pump.



First there was green gunk, now brown sh!t is coming out:






Enough with the oil pump... Moving on...

Trying to get the rotor wheel off the engine:



Another angle. It is not coming off and I am stuck at this point!

Alright guys, this is it for now. Thank you for viewing and commenting on this thread. You can also subscribe this thread to make sure you get all the latest updates !

Right now I am facing the following challenge. Main rotor nut has already been taken off the wheel. I really need to get the rotor wheel off but I guess the rust has gotten way too deep into the assembly. Any ideas how to remove this ???




Hopefully see you next week. (as I already mentioned that I am too lazy and work only on weekends ). Please feel free to ask questions, comments, suggestions, pointers, anything currently in your mind. That will help me a lot!

yor camera is amazing...loved the fly close up

you can keep the rest...far too picture heavy, takes an age to load up with my poor internet speed!

yor camera is amazing...loved the fly close up

you can keep the rest...far too picture heavy, takes an age to load up with my poor internet speed!

Thanks . It is just an ordinary point and shoot camera (canon brand, 4-5 years old).

As I mentioned in my very last post, I am having problems getting the rotor wheel off the engine. Any ideas / help / pointers are greatly appreciated

yes turn it until its tight and then hit the end with a heavy hammer, make sure its still tight and repeat

yes turn it until its tight and then hit the end with a heavy hammer, make sure its still tight and repeat

Thanks, i'll try it out.

One more thing. While removing the cylinder, I saw strange marks on the piston as shown below. Vertical scratches might be due to piston grinding with the cylinder walls. But what are these horizontal brownish lines on the piston?

of course the pistons are skimmed to size using a lathe, the marks you see are just carbon deposits in the grooves left by the machining process

Loved the photos Fakhir, your getting on really well, most of the stuff you call FUNGUS is just the aluminium reacting to moisture and neglect, just clean it with soap and water and then brush it off with a wire brush, make sure you don't breath this crap in as it is nasty stuff and your lungs will not thank you for it, most of the GREEN GUNK is just old oil that has separated during the years so again just wash it off and make sure you get right inside the part to remove it the BROWN GUNK is a bit more worrying as it is a mixture of oil and rust from inside the engine/pump that probably means that the seals are gone and any metal washers are also knackered just take it apart and replace anything that looks suspect. Airhead is the man when it comes to 2 strokes so if you have any advice from him I would just do it! The marks on the pistons are as he says just from when it was made so no real problem there but the coke (carbon) on the piston top looks a bit heavy so you might look at getting a new piston and rings as a part of the project plus measure the head/bore to see if it might need a re-bore and then you will have to replace all of that anyway. Nice work there mate should keep you busy for a while.

Loved the photos Fakhir, your getting on really well, most of the stuff you call FUNGUS is just the aluminium reacting to moisture and neglect, just clean it with soap and water and then brush it off with a wire brush, make sure you don't breath this crap in as it is nasty stuff and your lungs will not thank you for it, most of the GREEN GUNK is just old oil that has separated during the years so again just wash it off and make sure you get right inside the part to remove it the BROWN GUNK is a bit more worrying as it is a mixture of oil and rust from inside the engine/pump that probably means that the seals are gone and any metal washers are also knackered just take it apart and replace anything that looks suspect. Airhead is the man when it comes to 2 strokes so if you have any advice from him I would just do it! The marks on the pistons are as he says just from when it was made so no real problem there but the coke (carbon) on the piston top looks a bit heavy so you might look at getting a new piston and rings as a part of the project plus measure the head/bore to see if it might need a re-bore and then you will have to replace all of that anyway. Nice work there mate should keep you busy for a while.

How can I clean the components to make them like brand new? Petrol/Gasoline for cleaning appears to be extremely dangerous. Is there any equivalent that makes the parts spotlessly shiny but isn't flammable?

How about paraffin (kerosene) ?

How about paraffin (kerosene) ?

How are its cleaning abilities and is it totally safe to work with ?