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Gregs 2002 FS650 project / rebuild.

The new master cylinder used us a hayes stroker. It's ideal as it uses dot 4 at the brake fluid. It also has a long thin master cylinder body so can fit this with the standard clutch without to much of an issue. They are pretty cheap to. You can get a lit which allows you to keep your rear pedal to, but as I'd already removed it I just carried on without.


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Ah yes I see now. Just like my riding buddy has. This English dude Jason was riding on tarmac. One day had bad accident and opened up his right leg from just around ankle all the way to his hip. Now his ankle is fused and has massive scars. He's using this set up, left hand bar mount rear brake.
 
Been quiet for a few weeks now! Well the engine is in the process of being rebuilt. It's had a complete set of new bearings and the gearbox has been reassembled and put back in. The crank is away to be checked and bearing is getting replaced. The garage is a bit cold so I borrowed the kitchen lol.
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That's brilliant! I'm not the only one that rebuilds bikes and boat engines in the house dishwashers are great parts cleaners ,plastic chopping board was great to wedge and hold primary gears,my glass scales made a great lapping pad too.and it's so much cleaner in the kitchen compared to the shed.
 
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Yeah she's definitely a keeper.

The kitchen is great. Lots of tools and plenty of machinery to use.

Tonight's job was in the kitchen but Didnt really need to be.

New valve springs installed.

New front tyre arrived.

I wimped out with splitting the crank. Its not worth messing up. So I've boxed it up and sent it to Lancashire (gods county) to DCR to give it a once over and change the big end. I've also sent my liner and piston for him to check to see if it's all OK to reuse.

I'm currently wheelless.

Ive sold the behr rims and am currently awaiting delivery of some ktm mag wheels.

Lots going on and progressing quickly now the bits are here and I've got the time.
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Ive had news back from DCR. Great news the crank and Conrod are sound and ready to be used again.

The not so good news is that my liner is egg shaped and the piston is at the end of its life.

So I need another liner and piston before the build can go any further. [emoji17]

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Whilst the wheels are off and stripped though it would be a good time to get the Wheels coated. Added some sparkles to be a bit different. Whilst they are off and stripped I've got a full new set of bearings to put back in.

The replacement liner is back from being coated and I also have a new wossner modded piston to fit back in. The crank has been checked and big end bearing replaced. (another 350 gone)

I just need to find some time to rebuild her. Looks like I'm away this summer so may have to admit defeat and prep for 2019
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Awesome build work so far, really enjoyed reading this thread. Hope its put together soon and runs like a dream
 
Finally back home after 4 months pretending to be a fish under the ocean somewhere. I'll be cracking back on with the build soon enough. Just in time for winter.........

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Finally started on the engine. The main bits have been done. Just need to put all the small bits back on.

I've bought a full Carn rebuild kit. Might as well give the fcr a full spruce whilst I'm at it. Think I've come round to the fact it's not going to be back on the road until next summer
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he had the wrong piston in it but he wasn't my customer so i stayed out of it. Good luck!

Taffy
 
Taffy said:
he had the wrong piston in it but he wasn't my customer so i stayed out of it. Good luck!

Taffy
Click to expand...
Had the wrong piston in it….how on earth did that happen!?

Looks like it’s had a hard life since he owned. Been out on it a few times but going to start taking it to pieces in November and starting again!
 
Greg didn't trust what i said or it might be he didn't like the way i said it. Anyway, there's been an owner inbetween.

That piston is a 470 piston and DCR put them in a lot of motors. I'd say
"don't fit it"
, DCR would say whateever but because I'm blunt I lose all the arguments. I have the attitude of "look I'm phuqin tellin ya! it'll go bang".

"But he's promised me it'll go like a rocket!"
I'd say; "what you need is amahsnnrhdcysveyatshdkj"
(I didn't understand a word he said. he treats me like i'm 10 and the other guy is so sweet to me)

BANG!!!!!!!!!!!!!!

I might not say it "sweetly" but I'm always right.

With that piston, the compression is 16.3 to 1 which is nearly the same as a diesel. I know because I used a proper pipette, vaseline, paraffin, a dead stop lump, a TDC marker and a protractor! Then I did the maths which is easy.
liquid in chamber + CC (644)
divided by liquid in chamber = compression ratio. It took 42cc. you work it out.

but on days like this when I find out what happened when they didn't listen, I get SSSSOOOOOOOO much satisfaction!

Taffy
 
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Looking at the history there’s been two owners after Greg. Bike running ok now, slight oil leak between the block and the head and it requires just a tad of throttle (held open) to start once warm but it’s probably only got 2-3 more rides before I take it all apart again.

Is there an “easy” way to identify the piston when I take the head off?
 

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