fakhir

Now let's concentrate on the generator assembly: Another angle: Yet another angle: Zooming in on the generator a little bit: Coil closeup: More zoom:

Closer look at the flywheel magnets. There are a few signs of wear and tear but I don't know whether I should replace the flywheel or not. Closeup: There is rust on the wheel components but not as bad as rest of the bike. Still clearing this will prove to be a nightmare: The flywheel outer case also looks pretty beaten up. I wonder if would be able to reuse it: Zooming in. Rust but not too serious: Bit more zoom:

Flywheel from another angle. Now the magnet puller is totally stuck in the wheel LOL: Little zoom: Further zoom: Rusted surface on the wheel itself:

Alright, FINALLY got the flywheel off. I must say it is a very powerful magnet: (As you can also see the piston wrist pin is stuck) Flywheel closeup: A little more zoom:

But unfortunately the wrist pin is stuck inside the piston and is not coming out no matter how hard I try. I even used force (which I shouldn't have) and I think I made a tiny scratch on the piston as well . Well, i'll probably replace it if the condition is too bad.

Trying to remove the piston from the connecting rod: First you need to remove both of the circlips retaining the gudgeon pin, also known as wrist pin or piston pin: I used a nose plier to remove these circlips. Please note that these circlpis MUST NEVER be reused: Closeup: nose plier closeup:

Week 3 updates (19-May-2013) Hi guys, hope all of you are doing great. This time I wasted entire weekend trying to open up totally deformed screws with little or no success. Attached pictures show the progress. Since I don't have much material this week, i've taken quite a few useless closeups and macros LOL . Enjoy !!!

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

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?

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?

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

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!

Trying to get the rotor wheel off the engine: Another angle. It is not coming off and I am stuck at this point!

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...

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:

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

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.

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:

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

Ok, so we've got some visitors as well: Thank you Mr. Fly but i've got some work to do.... Moving 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?

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)

Let's view the piston in a little bit detail. We will come back to this in later stages of the restoration: Remember the engine on table: Let's do some closeups of the piston area. This is how the piston looks like from close. The amount of carbon is HUGE. REALLY zoomed in piston. THis pic is not clear (I REALLY need to get a decent camera). You can see the carbon deposits on the top side and the first ring:

Engine on the table. Side note: I really love that reflected reddish light. Cool photographic effect for free !!! Closer view of the rotor wheel. You can see the screws inside the wheel and how deformed they are. All I can witness is mechanic abuse EVERYWHERE !!! My advice: Don't open up your bike yourself if you want to avoid heart attacks... Gear shaft and drive shaft area: Closing in. Again, deformed screws. Screws don't melt like this in a harsh environment. This is the work of our awesome mechanics: Further zoom. Loads of gunk and stuff inside as well:

Closer look at the oil pump. Check out the deformed screw heads. Thank God I have my trusty impact screw driver along with me. Somewhere on top of the right side engine case. I wonder what kind of screw driver can open this one (except for impact driver)