Featured T595 Complete Rebuild (okay, Maybe Not "complete Rebuild")

Discussion in 'Builds & Projects' started by Jugg, Sep 21, 2021.

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  1. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Got most of the valves in tonight, very fiddly job but quite satisfying. Will put in the last few valves tomorrow night, chuck in the cams and check clearances.
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  2. Wessa

    Wessa Cruising

    Apr 27, 2016
    10,544
    1,000
    North West England
    That is looking very clean….
     
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  3. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Much better than when I stripped it that's for sure!
     
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  4. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Last 3 valves fitted tonight and clearances checked, they are all out of spec so will shift the shims about to suit and order some more for where I don't have.
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  5. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Landed lucky and am going to be able to move the shims about to get a lot of the clearances in spec. Muddled up my first sheet and instead of making the clearance tighter or smaller I was doing the opposite. Noticed in time before ordering a heap of shims so happy days! Just to figure out the 2 that have no clearance and can order shims needed.
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  6. Iron

    Iron Elite Member

    Dec 29, 2021
    2,138
    943
    Bob Ross Studios
    It's great when you can get your head round things. Just in the nick of opening the wallet up too. Good work. :cool:
     
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  7. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Swapped the shims about and double checked clearances. Need to order 3 shims and everything will be in spec happy days.
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  8. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    So I've beasted on with the bike this past week or so. Got the valve clearances finished and the new shims arrived and are in, fitted the head to the block, the engine back in the frame, fitted the cam chain, the throttle bodies, starter motor, alternator and fitted the covers back on. Of course I connected the throttle and the clutch cable so it felt like a bike again:joy: just waiting for a cam cover gasket and will finish the head off. Just need to fit oil cooler and lines, the coolant lines, and fix a few crimped wires with proper solder and we'll be good to go, hopefully the next couple weeks it'll be ready to start up... fingers crossed
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  9. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Everything buttoned up ready for pitting some oil in it. Exhaust manifold back on too so not too far from ready to start it up. Hopefully in the next week or so I'll be able to crank her over and see what happens. Fingers crossed she finds up and runs
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  10. Wessa

    Wessa Cruising

    Apr 27, 2016
    10,544
    1,000
    North West England
    Looking very good:)
     
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  11. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    So got the daytona all together today and before starting it I realised something was off with the gearbox and if anyone has been keeping up with this thread you'll know that after I put the 2 halves of the crank together I thought I built the gearbox wrong then convinced myself that it was right.... turns out it was wrong all along and neutral is between 5th and 6th.... DOH!

    So I thought since I was so close I thought I'd put it together to make sure it runs before I go tear it all apart again and I was a happy man as I eventually got it running good, only ran on 2 cylinders to start with as an ignition coil wasn't on right but she runs sweet as a nut and what a rip she's got.
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    So armed with some new motivation of hearing it run I'm going to crack on and rip it all out and fix my mistake. I've got an idea to make a bracket to hold the crank in place so the timing chain doesn't lose tension for when I split the 2 halves again so I have minimal work to get it back together. Will give it a go and see how it goes!

    I'm only human I suppose!!:joy:
     
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  12. Hubaxe

    Hubaxe Good moaning! aka Mr Wordsalad :)
    Subscriber

    Mar 25, 2020
    1,678
    800
    Aix Les bains - French Alps
    Still impressed. Good luck for the gearbox fix.
     
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  13. Wessa

    Wessa Cruising

    Apr 27, 2016
    10,544
    1,000
    North West England
    Yes good luck with the remedial work. Not be long before you will have it on the road.
     
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  14. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Thanks guys, was ready to sell it as an "unfinished project" when it was only running on 2 cylinders but I've calmed down and will get it sorted properly now:joy:
     
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  15. Tallpaul

    Tallpaul Noble Member

    Apr 7, 2019
    605
    393
    Kidderminster
    Fantastic effort so far mate, I'd be chuffed to bits if it was only a small error like that. 10/10
     
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  16. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Cheers pal, hopefully just an easy fix as not 100% on what bit isn't right so will soon see
     
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  17. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Everything stripped out the bike again and engine up onto the bench, left as much in the engine as I could so there's as few amount of bits to put back on after. Got all the upper crankcase bolts out, just to take out the bottom half bolts and make a wee bracket to hold the crank in place and can see what's going on.
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  18. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Got the wee bracket made up fir the crank and fitted it, nothing fancy but it does the trick!
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    Split the crankcase and all the internals look in good condition. Had a quick look at the gearbox situation and I think I've put one end of the selector drum out of sync to the other end so will consult the trusty haynes manual and see if I can't remedy the problem. I'm fairly confident it's the selector drum that's the issue though. Back inside early tonight to keep the peace with her indoors:joy:
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  19. joe mc donald

    Subscriber

    Dec 26, 2014
    13,705
    1,000
    slough / burnham
    Jugg
    Great job. Fantastic build. Now you will have a new steed. Well done you.
    Joe.
     
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  20. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    If it doesn't keep fighting me all the way i might even keep it a while:joy:
     
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