Urgent help needed

[Grahamm]

You could get a fibre optic scope to let you search the bikes innards without taking everything apart.

I think there are even ones with a little grab on the end so if you find the dowel in there you can pull it out.

[hightower]

I think I'd rather strip the bike than parting with another 50 quid

[hightower]

Will this do to seal the sump up again: http://www.ebay.co.uk/itm/2-x-GRANVILLE-...2a2f24dc0f


Was also thinking I could use that as a bit gasket for the cam chain tensioner?


Let me know, I'll order today thanks

[hightower]

OK, still waiting for dowel but got official sump gasket delivered today to decided to do that.

Took about 2 hours - cleaning the old gasket off with the engine in situ was a chew on, but got there.

Anyway, no missing dowel anywhere in sump. All cleaned up and fitted, do feel good making progress even though this missing dowel is killing me.

Hope dowel comes Saturday so can fit Easter Monday

[rodyork]

Walking away is a good idea at this point - I got frustrated a couple of weeks ago, and launched my 5mm thandle Allen key across the garage - no idea where it went, quite annoying not having it!!

Ive been there too!

[richfzs]

Bloody annoying, innit...

Still not as annoying as it'll be for hightower, when he's finished his rebuild, rolls the bike off the centre stand, and finds the wee dowel that was hiding just out of sight under the edge of the stand...

[hightower]

Believe me rich, I've checked lol.

I've rocked the bike side to side and everything. Still, I keep telling myself the bike has had a top end rebuild that would have cost a fortune in the garage.

[red98]

Will this do to seal the sump up again: http://www.ebay.co.uk/itm/2-x-GRANVILLE-...2a2f24dc0f


Was also thinking I could use that as a bit gasket for the cam chain tensioner?


Let me know, I'll order today thanks

morning hightower...i know you have bought a gasket but for future reference,ive used that sealer before and its one of the best on the market,good to have in the tool box 

[hightower]

I bought the paper gasket (which was easy to fit so worth getting I think) but I also bought some of that instant gasket too - as you say it just seemed a valuable thing to have, and I thought I could just use it on cct when I reinstall

[red98]

yeh be ok on the cct......being black helps,looks like a proper gasket unlike the red/orange stuff ,much neater 

[hightower]

Guess what arrived today - my dowels! Aj Sutton must have gotten them early. Gonna go out there this morning and get timing right and valve cover on - then Monday I can start to piece the rest together.

Excited

[ChristoT]

Guess what arrived today - my dowels! Aj Sutton must have gotten them early. Gonna go out there this morning and get timing right and valve cover on - then Monday I can start to piece the rest together.

Excited

But the dowel could still be in the engine?

Have you taken the head off to check inside the cylinders? Taken the cams out, and checked around the valves?

[hightower]

The only place I haven't checked is the cylinders. I wasn't prepared to buy new gaskets again for the very slim chance it was there. And I Jean very slim. I've shuck the bike and I would have thought I would hear it if it was in there. I've since done about 2 dozen hand cranks of the engine and it seems smooth with no hint of something in there.

I'm sure the dowel is stuck towards the rear of the bike perhaps lodged between some cables.

Like I say I was sure it wasn't in the engine but still took the time to check the sump etc. I've now 99.9% sure it's somewhere miles away from the engine so prepared to risk it

[ChristoT]

The only place I haven't checked is the cylinders. I wasn't prepared to buy new gaskets again for the very slim chance it was there. And I Jean very slim. I've shuck the bike and I would have thought I would hear it if it was in there. I've since done about 2 dozen hand cranks of the engine and it seems smooth with no hint of something in there.

I'm sure the dowel is stuck towards the rear of the bike perhaps lodged between some cables.

Like I say I was sure it wasn't in the engine but still took the time to check the sump etc. I've now 99.9% sure it's somewhere miles away from the engine so prepared to risk it

Do you have a magnetic grabber? It would only take a little time to take out the spark plugs, and introduce the tool into each cylinder to check - possibly slowly rotating the engine and stopping if you meet with any resistance?

[hightower]

Yeah, done that (was more scared I was going to drop that in lol). Even shoved it in the ports to double check there too

[hightower]

Well, guess what folks! It's back together, and sounding sweet as. Actually sounds like a bike now.


Took it for a little spin and all seemed tip top. Few photos attached for you to see. I've still got to get the bottom fairing on, need some new bolts and nuts to do it as old were shagged. Engine paint needs the smallest of touch ups on the fins too, just small marks from refitting head etc. But, all in all, it's had the valves lapped, all new gaskets, a good clean out, and a full service (oil, coolant, filters, plugs) so hopefully ready to go for the summer. It needs a bloody good wash and the fairing, but other than that it looks sorted.


And I'm sure you'll admit, it looks darn good with the black head and silver pipes. Maybe I can start and think about my KZ project now eh.


Oh, and guess what? The dowel dropped out. I couldn't believe it! I'd totally given up on finding it, expecting it to dislodge and drop on the road when I took it out. Anyway, pulled it out garage ready to clean chain, and dropped the side stand down, and lo and behold, there it is. I know what you're thinking, but I did drop the side stand to check. My guess is it moved there more recently (maybe after shaking the bike).


Anyway, alls well. Thanks everyone who contributed and helped me through this.

[red98]

Well done matey.....post a picture of the dowel to put all our minds at rest  :lol

[hightower]

Check out sig link. Big write up about it and some pictures lol.