Prince George Vintage Motorcycle Club

Technical Section => Complete Rebuilds => Topic started by: Hans on August 25, 2010, 08:25:50 AM

Title: Rebuilding Roseanne
Post by: Hans on August 25, 2010, 08:25:50 AM
Russ mentioned I should document my rebuild of Roseanne. 

(http://lh6.ggpht.com/_i1RdtzMrLUM/TG4QKg7RK6I/AAAAAAAAAKA/bV2ZPXzGn9w/s800/052.JPG)

Almost 97000km on the clock.  Burns some oil, pretty low readings on the compression test.  So found a bigbore kit on hte FJowners forum for a reasonable price.  1188cc to 1314cc in 420 easy steps.

(http://lh6.ggpht.com/_i1RdtzMrLUM/TG4QLhGZVgI/AAAAAAAAAKA/JP4aYDhSE0Y/s800/053.JPG)

Along with burning oil, she leaks oil too here and there, usually onto something hot.

(http://lh6.ggpht.com/_i1RdtzMrLUM/TG4QNcEu9AI/AAAAAAAAAKA/4i18cPDpftQ/s800/054.JPG)

Tank off, Carbs out, exhaust off and oil drained.

(http://lh4.ggpht.com/_i1RdtzMrLUM/TG4QOU9MaoI/AAAAAAAAAKA/NCQS_wzrACU/s800/055.JPG)

My work area, the netbook has a pdf version of the service manual (thanks Ken) and also streams from my iTunes server so I have music.  Also have a paper service manual.  There are several instances where the 2 manuals don't agree....   The first days work was a 2 beer process.

(http://lh4.ggpht.com/_i1RdtzMrLUM/TG4QQYR8-3I/AAAAAAAAAKA/w4Gc32d37hY/s800/001.JPG)

One very grungy engine out of the frame.  This lump is friggin heavy.

(http://lh3.ggpht.com/_i1RdtzMrLUM/THICQTtXi_I/AAAAAAAAAKQ/lPeITchxr1g/s800/001.JPG)

Garden carts are useful for something.  Make great wash carts.  Once can of WD40, 2 cans of engine shampoo, lots of hot soapy water and a pressure cleaner, and this is still pretty grungy.

(http://lh5.ggpht.com/_i1RdtzMrLUM/THICWVH909I/AAAAAAAAAKg/s0XwSyqSGk4/s800/003.JPG)

Disassembly begins.  The head was tough to get off, the gasket kept hanging up on the studs.

(http://lh3.ggpht.com/_i1RdtzMrLUM/THICaj2Gz5I/AAAAAAAAAKw/asPlf7f3XRQ/s800/006.JPG)

Several of the stubs were supposed to have a rubber sleeve on them.  Heat and age broke this down into granular bits which promptly went into the lower end when I lifted the cylinders.

(http://lh6.ggpht.com/_i1RdtzMrLUM/THICYOQP1yI/AAAAAAAAAKo/wLwbqZMGnHc/s800/004.JPG)

Head look pretty good.  Just going to clean it up and do that valve seals.

(http://lh5.ggpht.com/_i1RdtzMrLUM/THICZCuGSbI/AAAAAAAAAKs/aD007VdAMyU/s800/005.JPG)

Pistons look not too bad either.  Some pretty bubbly carbon deposits from burning a bit of oil.

(http://lh3.ggpht.com/_i1RdtzMrLUM/THSv5TBddtI/AAAAAAAAAK0/OtBWWSo-nVs/s800/009.JPG)

Cases split.  There was one hidden bolt not referred to in one of my manuals. 

(http://lh6.ggpht.com/_i1RdtzMrLUM/THSv-cgUvXI/AAAAAAAAALA/jMPQVZK5U58/s800/012.JPG)

Will be looking at 2nd gear while this is apart.  Pay no attention to the Crappy Tire oil filter.  It was just there to keep water out when I was cleaning the engine.

(http://lh6.ggpht.com/_i1RdtzMrLUM/THSv6ylKr5I/AAAAAAAAAK4/DPPT7R5UhP8/s800/010.JPG)

Crank comes out with the top case.

(http://lh6.ggpht.com/_i1RdtzMrLUM/THSv8mKr8OI/AAAAAAAAAK8/RYqFwQnMx8s/s800/011.JPG)

Crank out of the top case, it's ready to go visit the machinist.  I have to pay a couple visits to my friendly neighbourhood Yamaha dealer.
Title: Re: Rebuilding Roseanne
Post by: Fritz on August 25, 2010, 09:10:27 AM
Good Work Hans...
Looking Forward to all   420   Steps   ;D
Title: Re: Rebuilding Roseanne
Post by: Hans on October 01, 2010, 10:27:02 PM
A couple of more pics to add.  Have had Jeff machine the cases.  New barrels now fit nicely.

(http://lh3.ggpht.com/_i1RdtzMrLUM/TKa-qx2xlVI/AAAAAAAAALs/VZvYGhLUo-Q/s800/061.JPG)

Piston in the middle is as it came out of the engine.  Piston on the left is after a week in the varsol tank and a little bit of scraping with a plastic putty knife.  Cleaned up pretty good.  Piston on the right is what will be going into Roseanne however.

(http://lh3.ggpht.com/_i1RdtzMrLUM/TKa-sJ9UMQI/AAAAAAAAALw/UxbgdhBIhjQ/s800/063.JPG)

Here you can see the difference in bore.  77mm to 81mm

(http://lh4.ggpht.com/_i1RdtzMrLUM/TKa-tays5RI/AAAAAAAAAL0/7fWwu4hjJkY/s800/065.JPG)

Dome is a bit higher also.  Compression goes from 9.7 to 10.25.
Title: Re: Rebuilding Roseanne
Post by: Admin on October 04, 2010, 02:16:16 PM
And only 400 more steps to go
good job H
Title: Re: Rebuilding Roseanne
Post by: Donovan on October 04, 2010, 04:42:53 PM
Hans looks great, I will have to have you give me lessons on rebuilding engines when my turn comes.  Eager to see some more pics.

Donovan
Title: Re: Rebuilding Roseanne
Post by: Fritz on October 15, 2010, 05:29:30 PM
The piston pics show a great story....

Have you got them back into the barrels now?
Title: Re: Rebuilding Roseanne
Post by: Hans on October 15, 2010, 08:13:09 PM
Nope, still waiting for a few more parts, cam and starter chain and guides.  Then the real test begins.  I can take it apart, but can I get it together?
Title: Re: Rebuilding Roseanne
Post by: Hans on October 18, 2010, 10:47:33 PM
Some more progess.  Head is still at Jeff's getting his porting and polishing treatment.  Still wating for a cam and starter chain, should be here next week.  Then I can start assembly for real.  In the meantime.......

(http://lh5.ggpht.com/_i1RdtzMrLUM/TL0wYytQMAI/AAAAAAAAAMo/n0bWXDt062c/s800/014.JPG)

Decided to put the transmission back into the lower case.  As per normal, the one manual say to assemble it into the top case, the other into the lower case.  I'm going to try the lower case method.  This is just the shift drum.  Still haven't found the mythical 6th gear.  Had to wash the cases in the downstairs bathtub (I asked first).  Washed some really filthy parts in the varsol tank and the fluid got horribly contaminated with really fine silt.  Have to clean it out, but in the meantime, the aluminum stuff can get washed in soap and water. 

(http://lh5.ggpht.com/_i1RdtzMrLUM/TL0waYDyMsI/AAAAAAAAAMs/taAJQxQNC2o/s800/015.JPG)

Gearset back in.  Would have been easier if I had 3 arms and hands half the size.  Eventually got it figured.

(http://lh6.ggpht.com/_i1RdtzMrLUM/TL0wbsuO5KI/AAAAAAAAAMw/k1IDPL6UkSk/s800/018.JPG)

This is the Factory Pro shift kit.  The detent arm has a bearing instead of just a bushing and the spring that came with it is about twice as stiff.
Title: Re: Rebuilding Roseanne
Post by: Hans on October 20, 2010, 09:31:06 PM
Going great guns now.  Thought I'd get a little jump on the matter and get the rods onto the crank.  New bearings and all.

Look, I'm almost organized.

(http://lh3.ggpht.com/_i1RdtzMrLUM/TL_CUCPzPrI/AAAAAAAAAM0/pAiqlClQ6G0/s800/002.JPG)

First one on...

(http://lh5.ggpht.com/_i1RdtzMrLUM/TL_CVMDF76I/AAAAAAAAAM4/u7kz4V1Ctcw/s800/003.JPG)

And a half hour later, the rest.  According to the book, I even have them on the right way.

(http://lh5.ggpht.com/_i1RdtzMrLUM/TL_CWYiswYI/AAAAAAAAAM8/hh8ww7pnbD8/s800/004.JPG)
Title: Re: Rebuilding Roseanne
Post by: Rusty Bucket on October 21, 2010, 09:26:19 AM
Eww, rod bolts. :D  I put a roller shift cam bearing in place of a nylon wheel on the shift cam of my BMW, certainly more precise feeling;  almost too positive.  Somehow it seems more likely to leave a sore spot on your foot now.  The bearing I put in had to come to Kaman through a clock maker in Vancouver and set me back $50...
Title: Re: Rebuilding Roseanne
Post by: Hans on October 22, 2010, 09:56:23 PM
Got my head back from Jeffries While-U-Wait Porting and Polishing Emporium.

(http://lh6.ggpht.com/_i1RdtzMrLUM/TMJrdeYWq1I/AAAAAAAAANE/hnjAM86qHR4/s800/002.JPG)

A couple closeups of his work

The chamber

(http://lh3.ggpht.com/_i1RdtzMrLUM/TMJrgMrMb2I/AAAAAAAAANQ/k0oCcKU0eSM/s800/004.JPG)

The intake

(http://lh5.ggpht.com/_i1RdtzMrLUM/TMJrhVdpboI/AAAAAAAAANU/X-K-JNpUAZo/s800/005.JPG)

The exhaust

(http://lh6.ggpht.com/_i1RdtzMrLUM/TMJregGZrVI/AAAAAAAAANI/_IwVj2QpfQg/s800/003.JPG)

Started lapping in the valves, got through the exhaust side tonight.  Need opinions, did I do the one on the right enough.  On the left is the before shot.

(http://lh4.ggpht.com/_i1RdtzMrLUM/TMJri84O8xI/AAAAAAAAANY/M5amrA-FkII/s800/006.JPG)

Off to watch F1 qualifying now.
Title: Re: Rebuilding Roseanne
Post by: Hans on October 24, 2010, 10:52:27 PM
Started putting the valves back in tonight, got one cylinder done before I felt like calling it a night.  Here's a before and after shot of Jeff's work.  Not the same angle, but you can get the idea.

Before

(http://lh3.ggpht.com/_i1RdtzMrLUM/TMUcn33eNGI/AAAAAAAAANk/IJtVUWoK8pA/s800/before.png.jpg)


After

(http://lh3.ggpht.com/_i1RdtzMrLUM/TMURuEHFhlI/AAAAAAAAANg/BYiMrPcmbMw/s800/001.JPG)
Title: Re: Rebuilding Roseanne
Post by: Hans on October 25, 2010, 10:03:14 PM
Got the head finished.  If anyone needs to borrow a valve spring compressor, my Princess Auto one didn't explode halfway through the job.

(http://lh6.ggpht.com/_i1RdtzMrLUM/TMZhQd6qswI/AAAAAAAAANo/DjfZTduF1Kc/s800/001.JPG)

New seals, a lovely green colour.

(http://lh5.ggpht.com/_i1RdtzMrLUM/TMZhSPd-QAI/AAAAAAAAANs/YotlfbqqI0o/s800/002.JPG)

(http://lh6.ggpht.com/_i1RdtzMrLUM/TMZhTsOdkfI/AAAAAAAAANw/Z6LQ64oSSgU/s800/003.JPG)

All in, in dire need of a parts shipment before further progress is to be made.

(http://lh3.ggpht.com/_i1RdtzMrLUM/TMZhU6nRHRI/AAAAAAAAAN0/AugNf5KnNcs/s800/004.JPG)

(http://lh4.ggpht.com/_i1RdtzMrLUM/TMZhWryvOgI/AAAAAAAAAN4/bb7Z9LSBbqE/s800/005.JPG)
Title: Re: Rebuilding Roseanne
Post by: madmac74 on October 26, 2010, 05:38:06 PM
aaahhhh yes Memories!!!!   ;D ;D  Lokking good Hans...  Is that a Bergman spin-on oil filter adaptor?
MAC :)
Title: Re: Rebuilding Roseanne
Post by: Hans on November 01, 2010, 10:13:06 PM
Parts arrived today, so off we go......

Piece with the white gooey assembly lube is a starter chain guide, was waiting for this.  New bearing shells in too.

(http://lh5.ggpht.com/_i1RdtzMrLUM/TM-cbqGnttI/AAAAAAAAAOU/FuCy5XDvqpo/s800/006.JPG)

Old starter clutch, new starter chain, new cam chain and crank into the top case.  The big ass chain only does the starting duties.

(http://lh5.ggpht.com/_i1RdtzMrLUM/TM-cbqGnttI/AAAAAAAAAOU/FuCy5XDvqpo/s800/006.JPG)

Two case halves almost ready to meet.  Have to find out whether my crank seal is correct.  The baggie had the right part number, and the ID and OD are correct, but the old one had a flange on it and the new one doesn't.

(http://lh3.ggpht.com/_i1RdtzMrLUM/TM-chDejZdI/AAAAAAAAAOg/VyOsbUeXmww/s800/010.JPG)

Title: Re: Rebuilding Roseanne
Post by: Hans on November 03, 2010, 09:59:11 PM
Got the case halves together tonight.  Note to self, when using threebond, wear an OLD sweatshirt.  I now have a new old sweatshirt.

(http://lh5.ggpht.com/_i1RdtzMrLUM/TNI_H3DjuGI/AAAAAAAAAO4/QNpEOwvPtW4/s800/001.JPG)
Title: Re: Rebuilding Roseanne
Post by: Hans on November 04, 2010, 11:30:39 PM
Long but productive night in the garage....

Pistons on the rods.

(http://lh6.ggpht.com/_i1RdtzMrLUM/TNOlMW4lE8I/AAAAAAAAAO8/dpFnNPN3fic/s800/002.JPG)

Starting to drop the cylinders.  Should have bought 4 hose clamps.

(http://lh6.ggpht.com/_i1RdtzMrLUM/TNOlOR0JiXI/AAAAAAAAAPA/CKfehtmOfvg/s800/003.JPG)

Part way down

(http://lh4.ggpht.com/_i1RdtzMrLUM/TNOlQbp7P6I/AAAAAAAAAPE/fDVtdylcxpE/s800/004.JPG)

And then I had to do it again.  Look on the right and tell me if you see the problem. 

Cylinders all the way on.  Whoo hoo, couldn`t stop here.

(http://lh6.ggpht.com/_i1RdtzMrLUM/TNOlR09flWI/AAAAAAAAAPM/dncr00WPnQI/s800/005.JPG)

Head on

(http://lh4.ggpht.com/_i1RdtzMrLUM/TNOlTkIS3BI/AAAAAAAAAPQ/uFTqk5vuKkI/s800/006.JPG)


Cams in, but the timing is way off.  Got too late to continue, so onwards later.

(http://lh5.ggpht.com/_i1RdtzMrLUM/TNOlW4fOaoI/AAAAAAAAAPY/CO7Ewy7Y6H8/s800/008.JPG)
Title: Re: Rebuilding Roseanne
Post by: Fritz on November 05, 2010, 10:08:10 AM
Quote from: Hans on November 04, 2010, 11:30:39 PM






(http://lh4.ggpht.com/_i1RdtzMrLUM/TNOlQbp7P6I/AAAAAAAAAPE/fDVtdylcxpE/s800/004.JPG)

And then I had to do it again.  Look on the right and tell me if you see the problem. 



Oh well......"Practice makes perfect"...No stopping ya now....with this weather you will be Ridin' it in no time...
Looks Good Hans....( for a Yamaha  ;D ;D)
Title: Re: Rebuilding Roseanne
Post by: Fritz on January 01, 2011, 11:41:52 AM
How's the Build going there Hans....Are you still waiting for it to Warm up a bit?
Or...are you looking for an MX175 to work on... ;D
Title: Re: Rebuilding Roseanne
Post by: Hans on March 25, 2011, 11:37:58 PM
OK, back at it the last couple of nights.  Warm enough to work.  Last night was trying to remember where I left off, and trying to find whatever parts I need to throw at this thing.  Tonight was clutch cover on, clutch pushrod in, measure valve clearances (have to buy 10 shims...), and the alternator and starter back in.  Just have to set the valves and put the oil pickup and pan on, and it's a done deal. 

(https://lh3.googleusercontent.com/_i1RdtzMrLUM/TY2JYbZkdWI/AAAAAAAAAU0/H-LQ9ko3VSc/s800/358.JPG)
Title: Re: Rebuilding Roseanne
Post by: fj1200 on March 25, 2011, 11:55:03 PM
Good on you Hans.   :)
Title: Re: Rebuilding Roseanne
Post by: madmac74 on March 28, 2011, 06:54:06 PM
 Are they 13mmm Diameter shims ??  if so I have a wide assortment .....


O an good on ya mate !!!!

MAC :)
Title: Re: Rebuilding Roseanne
Post by: Hans on March 28, 2011, 07:34:39 PM
Nope, 29mm. Happened to 'acquire' some. Valves are set, oil pan is on. All would be good if I had the right cam cover gasket. Somehow I got one for an FJ600......
Title: Re: Rebuilding Roseanne
Post by: Hans on March 30, 2011, 10:26:25 PM
And...  I think I'm done...  Need to get 4 orings for the carb boots, and should give the carbs a bath at Jeff's Ultrasonic Emporium.

Final product... still doesn't look too pretty, but then she is named Roseanne.

(https://lh6.googleusercontent.com/_i1RdtzMrLUM/TZQN62vybOI/AAAAAAAAAVc/irWU3aVqFao/s800/002.JPG)

(https://lh6.googleusercontent.com/_i1RdtzMrLUM/TZQOWFnN9rI/AAAAAAAAAVk/Wi_W65niCVw/s800/006.JPG)

(https://lh5.googleusercontent.com/_i1RdtzMrLUM/TZQOX_mJOKI/AAAAAAAAAVo/Bk42cChCIYM/s800/004.JPG)

When it comes time, somebody please remind me to tighten that countershaft sprocket.....
Title: Re: Rebuilding Roseanne
Post by: Fritz on March 30, 2011, 10:38:26 PM
Looks Good Hans....Really like the Red Stripe  ;D
Don't forget to tighten the countershaft sprocket..... 8)
Title: Re: Rebuilding Roseanne
Post by: Rusty Bucket on March 31, 2011, 11:23:26 AM
I have a wrench that grabs small sprockets so you can hit their retaining nuts with an impact wrench or a big torque wrench, while still on the bench:  I wonder if it would happen to fit the output on the FJ? I guess a strap-wrench style chain-wrench would be truly adjustable and still take the hit from the impact gun or the torque from the torque wrench...I should build one.
Title: Re: Rebuilding Roseanne
Post by: Hans on May 23, 2011, 07:39:29 PM
Got busy today, engine back in frame, carbs on.   figure first fire on Wednesday, maybe.
Title: Re: Rebuilding Roseanne
Post by: Fritz on May 26, 2011, 11:05:06 PM
So.....How's it running?.....

[attachment deleted by admin due to full attachment storage]
Title: Re: Rebuilding Roseanne
Post by: Hans on May 26, 2011, 11:21:23 PM
poorly.  something not correct in the top end, gonna have to open er up and have a look..........
Title: Re: Rebuilding Roseanne
Post by: Hans on June 08, 2011, 10:56:19 PM
I said frig it tonight, and fired er up again.  Horrid noise wasn't so horrid....  Shut her down, checked the oil level.  Added almost a litre, sparked her up, sounded OKish, getting better as she ran.  Maybe more oil helped, maybe something needed to settle in... dunno, but she sounds mean now, even vicious.  Might have to try and take her for a ride.
Title: Re: Rebuilding Roseanne
Post by: fj1200 on August 15, 2011, 12:24:21 PM
Haven't seen anything in awhile about Roseanne. Is she up and runnin or still feeling poorly???
Title: Re: Rebuilding Roseanne
Post by: Hans on August 15, 2011, 09:34:17 PM
Went up and down the street once, didn't feel too good at all.  Decided I could still hear the disturbing noises and put her away.  No there is puddle of oil underneath that will have to be investigated.  Also weeping oil at the base gasket.  When I get some time (famous words those) going to pull the engine from the frame again and investigate further.  In the meantime, the FZ1 starts, runs, turns, stops.  Roseanne was never good at the last 2, now not so good a the first 2.  Weren't you going to sell me an FJ engine for $100 and 2 cases of beer??
Title: Re: Rebuilding Roseanne
Post by: fj1200 on August 15, 2011, 10:15:03 PM
I do believe that was your offer and if there isn't more action who knows what could happen. ::)  Although the weather hasn't been too conducive to drinking cold ones. :(

Are you going to take the fz1 out to the track this year?  No bikes running this past friday just the Northland sled that spun all the way to end and still did 11 sec.
Title: Re: Rebuilding Roseanne
Post by: fj1200 on February 06, 2012, 03:34:37 PM
Hans. I was just sitting here daydreaming about summer and started wondering how Rosey was doing? Anything up yet? This will also keep the thread alive as well.



[attachment deleted by admin due to full attachment storage]
Title: Re: Rebuilding Roseanne
Post by: Hans on February 07, 2012, 09:55:01 AM
nothing as of yet, still buried in the back of the garage.  Too many other projects and annoyances to deal with at the moment.