Time for a Task List

It's quite easy to be overwhelmed with what has to be done in order to bring this project to some sort of completion without it becoming a collection of parts in my garage for years to come. So here's what is left to be done.

Clean the remaining pistons.
Finish cleaning the lower crankcase
Mask the lower crankcase in preparation for painting.
Paint lower crank case with multiple coats.
Measure the piston ring end gaps - determine if new rings are needed.
Clean upper crank case
Mask upper crank case in preparation for painting.
Paint upper crank case.
When new rods & crank arrive:

• Measure piston pins and compare to my existing piston pin. Determine if the clearance is within service limits.       

• Use plastigauge and measure new crank pin bearing clearances and measure crank case bearings using existing bearings with new crankshaft. Determine if the clearance is within service limits.

Clean oil sump
Mask oil sump ready for paining
Paint oil sump
Use compressed air to blow out dirt from oil channel in lower crankcase
Install gear selector drum in lower crank case & lubricate
Install pistons with new rods & new crankshaft in upper crank case
Install transmission in upper crankcase & lubricate
Order a full gasket set
Combine the upper and lower crank case.
Clean oil strainer
Reinstall oil sump.
Check oil pump clearances and determine if replacement is necessary
Reinstall oil pump
Reinstall stator flywheel & clutch housing and clutch
Reinstall crank timing sprocket
Clean timing cover & repaint
Clean clutch cover & repaint
Clean stator cover & repaint
Clean oil cooler and repaint
Order new oil cooler bolts
Install oil cooler.

Cylinder Head Service
Remove valves and clean & check and remove carbon deposits
Reinstall valves and check installation
Clean cylinder head intake and exhaust ports.
Repaint cylinder head.
Install cylinder head using new gaskets & ensure correct timing
Perform a valve clearance check & service if necessary using new shims
Order a new thermostat (old one needs replacing).
Clean valve cover and repaint
Install valve cover with new gasket.

Engine Complete

Remove rust from front of bike frame and repaint
Remove ohlins shock.
Remove rust from shock spring and repaint
Determine if Ohlins shock to be serviced by an Ohlins specialist
Remove rust from head light, mirrors and lower fork mounting clamp

Reinstall Engine
Order new Pair Valve pipes & Gaskets & Bolts
Order correct engine oil
Order correct oil filter & install.
Fill with OIL!

Carburettor Service
Clean & check carbs - dismantle if necessary.
Reinstall carbs after service
Clean air box & radiator, remove rust & repaint if necessary.
Order new stator wiring connector

Fill with engine coolant.
Engine first start.
Get air out of coolant and ensure coolant at correct levels.

Service front and rear brakes & clean - replace brake fluid, determine if new pads are needed.
Examine wiring and get brake light working.

Clean wheels.
Order new Tyres & Install



Things to Order
Order a full gasket set
Order new oil cooler bolts
Order a valve spring compressor
Order a new thermostat (old one needs replacing).
Order new Pair Valve pipes & Gaskets & Bolts
Order correct engine oil
Order correct oil filter
Order new stator wiring connector
Order new Tyres