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July 19th, 2014, 06:06 PM   #1
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Bushmechanic Mongrel 628 Trailbike

bits of this build don't really fit anywhere so ill put them here

I'm building a 628 from bits i have laying around, only stuff i really had to buy were cases head crank/piston.

Originally Posted by bushmechanic View Post

Scored a smoking hot deal on Ebay, absolute best ever internet buying experience, no BS listing good price 4 days to get here from the states beautifully cleaned parts in top condition you could eat off these! and very well wrapped too. never seen anything like it before

lineaweaver big valve racing head



mint 01 650 cases... they are in better condition than my 08 cases





:
Big thanks to Mopwer for a smoking deal on these parts.. best ever internet shopping deal.
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July 19th, 2014, 06:12 PM   #2
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I think I started on the crank first

Balancing an 80mm 650 crank



Originally Posted by bushmechanic View Post
cut off the counterbalancer drive gear and champhered a lead in for the oilseal




Last edited by bushmechanic; July 19th, 2014 at 06:35 PM.
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July 19th, 2014, 06:17 PM   #3
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steel sleeves in the cases to house 22206 spherical roller mains

Definative main bearing thread

Originally Posted by bushmechanic View Post
drive side



drilling oil pressure gallery to the drive main







the old cases don't have the drip feed to the RHS main so I drilled one, will make a dam to catch more oil



decide to install a second piston



sleeves



RHS main bore with sleeve



LHS main with 1mm diam jet



3.5 thou interference fit between the cases and the sleeves

need to go back in the mill and be final sized to a 2 thou interference fit with the bearings.

also re machining the oil pump cavity to take the 15mm wide ktm atv rotor


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July 19th, 2014, 06:23 PM   #4
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Valve Spring upgrade

milled out clearance for the KTM Dual valve springs, can also see the small pocket i put in to take the pivot for the newer cam chain tensioner



checking seated force in the CNC mill



checking for maximum travel from installed height to coil bind



measured 13.5mm

Thanks from kli and WArdogG

Last edited by bushmechanic; July 19th, 2014 at 06:51 PM.
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July 19th, 2014, 06:30 PM   #5
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Rocker arm damage from failed Cam follower

intake cam lobe had failed in this engine, intake cam follower bearing was stuffed

the rollers gouged out the rocker arm sides



resurfacing

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July 19th, 2014, 06:38 PM   #6
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Crankcase Venting 101

Originally Posted by bushmechanic View Post
second reed valve 02 650





free HP no blowby and still allows oil mist lube where it is needed
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July 19th, 2014, 07:13 PM   #7
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finally found some old parts that even I think need a clean





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July 20th, 2014, 01:52 AM   #8
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Love ya work bush....
Hope keep posting till its finish project
Very clean indeed motor
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July 21st, 2014, 04:55 PM   #9
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that took a while and its still not finished





now i know why "real" mechanics are so grumpy... spend all day making things look good on the outside to convey the impression of competent work inside LOL
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July 22nd, 2014, 03:44 PM   #10
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Top stuff Bushie
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Last edited by steve; July 23rd, 2014 at 04:09 PM.
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