Email Conversation
On Tue, 07 Jan 2025 at 14:27, Jon wrote.
This is Jon, just sending you my details with my BSA with the engine issue (big ends) you collected today.
On Mon, 13 Jan 2025 at 16:25, Terry wrote.
I am nearly there with the bike. will hope to have it back together on Thursday. The mains bearings were shot and the oil seals were as hard a concrete. whoever built the engine done a very good job overall as there was no butchery. But there was sealant floating about throughout the whole engine including the oil pump.
On Mon, 13 Jan 2025 at 16:40, Jon wrote.
Ok great news. Thanks for the update.
On Wed, 22 Jan 2025 at 0:09, Terry wrote.
Bike is all done, everything fitted and working.
On Wed, 22 Jan 2025 at 6:23 Jon wrote.
Ok great, will pop over Tomorrow.
On Wed, 22 Jan 2025 at 08:53, Jon wrote.
Just for history for the bike, can I have a full breakdown of what has been done (just the engine) as a receipt on headed paper please.
On Wed, 22 Jan 2025 at 11:05, Terry wrote.
The breakdown has been printed.
On Wed, 22 Jan 2025 at 11:14, Jon wrote.
Perfect.
On Thu, 23 Jan 2025 at 16:01, Jon wrote.
Payment has been made and should be in your account now. Let me know when you can drop it over.
Breakdown
Bottom End
• Remove engine and all attachments.
• Strip engine down to component parts.
• Clean all parts including crank shaft sludge trap and oil pump
Internals
• Replace mains roller bearing.
• Replace mains bronze bearing.
• True up crank shaft to .001″ total run out.(not running true).
• Make new crankshaft end fload shim.
• Replace all oil seals.
• Fix 2 stripped threads in timing side casing.
• Fit missing locating dowels into timing casing.
• Change little end bronze bush.
• Findings for bottom end.
• Lots of nuts and bolts were very loose and an engine mounting bolt was Cross threaded and very awkward to remove.
• Spring washers were fitted to a lot of internal parts that didn’t need them.
• The oil seals through the engine were rock hard.
• The mains roller bearing was absolutely worn out and rattily.
• The timing side bearing was .010″ worn and oval.
• The crank shaft was running out by .012″ total, I feel the timing side bearing had been hand scraped to accommodate the crank run out.
• The missing location dowels in the timing side cover are critical load bearing components as they support the area where the kickstart spindle goes through. without them fitted there would be immediate wear to the casing due to shear stress or a broken casing at worst and a terrible oil leak from kick start spindle. i have seen dowels left out as a lot of builders think they are just there to line the casings up but they are there to line the kick start spindle supporting hole in the outer casing in line. if the dowels are left out there would be so much stress through the gearbox.
• Little end bush had .003″ wear.
• There was a lot of sealant throughout the engine internals.
Top End
• Hone barrel to remove glazing.
• Anneal cylinder head gasket.
• Replace cylinder base gasket.
• Decarbonize cylinder head.
• Remove valves and grind in.
• Clean piston crown.
• Repair 2 off rocker box threads.
• Rebuild engine and fit all components.
• Clean internals of distributor and set ignition timing.
• Adjust valve clearances.
Fuel System
• Clean carb internals.
• Reset needle into correct position (the setting was too rich).
• Change pilot jet to smaller one (too rich).
• Remove inline fuel filter (causing air lock in fuel line).
• Fit new fuel line.
• Clean fuel tap and its filter.
• Replenish fuel.
• Top up oils.
• Test engine to give best starting and running.
Findings with Fuel System
When the carb was built it was only set up for easy starting and would
have been horrible to ride with a very smelly exhaust. For some reason there is no choke fitted so one has to cover the air intake with a hand to act as choke and the bike will start easily. The engine runs and idles perfectly.
Electrics
All electrics are good and new but there is no brake light switch on the brake pedal.
Pictures
All done in three days with help from our extensive machine shop and new old stock parts.
