Bank Holiday Engine Change

[tony22]

My trusty commuter finally getting some tlc.. After 105k of trouble free running I’ve decided to replace the engine as the thread on the output shaft is stripped and the splines are really worn, managed to get a low millage engine of eBay pretty cheap so rather than replace the output shaft I’m going to do a straight swap, if it turns out the eBay engine is no good i will strip the two down and swap the gearbox's over.

Belly pan removed



Had to get creative to get the engine out on my own..





While the engine is out I’m going to give the frame a repaint at the front as the winter commuting has taken its toll.

Will video the first start of the replacement engine as it hasn't run for 6 years.. All looks good inside and compression is good so hopefully should be drama free.

[Dave48]

Now all you have to do is pray it doesn't rain!  :lol

[Chris]

Hope it all goes well for you!

Chris

[tony22]

Now all you have to do is pray it doesn't rain!  :lol

Yeah I know, im up ready to get cracking but i said to the missus yesterday she could have a layin this morning  :z

Not using the garage as it has this in it, in nut and bolt form..

[tony22]

Mission of a day, got the frame repainted, engine in with no problems. Except for a school boy error, i put the throttle cables on wrong and only noticed when i had just tightened up the last clamp. Anyway once that was all sorted and filled with fluids i turned it over without the coils connected to let the oil system prime itself, connected the coils and it rattled to life. Think the cam chain tensioner needs time to sort itself after i took it out to see how much adjustment was left. But once it had been running for a few minutes it seems to run fine no smoke or and nasty noises so happy days Just need to fit my new chain and sprockets and take it for a test run.

I recorded it's first start if anyone is interested I will upload it.

[red98]

You done well there tony......your new engine was that the cheap one on ebay last week ?

[tony22]

You done well there tony......your new engine was that the cheap one on ebay last week ?

No picked this one up from Bristol about 6month ago.. £60 quid as the guy couldn't guarantee it was a runner

[tony22]

http://youtu.be/XMYN9mi37xw

http://youtu.be/P0zhyvNKzgI

Has anyone got a carbtune / balancer i could borrow for an afternoon, im in Chelmsford essex?

[darrsi]

http://youtu.be/XMYN9mi37xw

http://youtu.be/P0zhyvNKzgI

Has anyone got a carbtune / balancer i could borrow for an afternoon, im in Chelmsford essex?

I was gonna say your carbs need balancing then saw what you wrote after watching your videos.
All sounds good other than that, not even a hint of cam chain noise, you've done a nice job there Tony. 

[bristol banger]

Nice work, always a good feeling when a newly fitted engine burst into life for the first time

[Dave48]

So the rain Gods were looking after you! Well done-Result now all you've got to do is scrub the patio etc :lol

[tony22]

wow gte with mk3 gsi wheels, is your gte a redtop sir?

bet the missus loves you taking over the patio

It is indeed an early 16v, not on any wheels at the moment and I have a GT Turbo in a non-moveable state on the garage drive hence me taking over the patio

Finished up today, removed the swing arm to clean and regrease, new chain and sprockets on, love how smooth a new chain and sprocket set is, gone for another DID gold xring.

Now all I need to do is take it for a test ride tomorrow morning, hopefully the rain will have passed by then.

[Gav]

Nice one, you've done a good job by the looks.  Bargain engine too, well done. For 60 notes to swap out a tired engine with a fresher one = no brainer! 

Perfect timing too, decent weather here (ish / almost)

[red98]

well done tony,a bank holiday well spent    good luck with the test ride this morning.

[tony22]

Thanks guys, lovely sunny morning for a ride out, never really get to go out apart from the daily commute so took a steady ride down some great twisty B roads. Pulled over after a few miles just to check for leaks etc engine sounds perfect now even the carbs seem to be pretty well balanced, didn't rev it to hard only up to 8k but it pulls great and the gearbox is very smooth so well pleased. Defiantly worth the gamble..

[tony22]

200 miles on the new engine, so far so good. Only issue being a leaking sump bolt.. finger tight isn't a good idea, whoops.

[Dave48]

Hopefully everything else is tight!!

[tony22]

Hopefully everything else is tight!!

Gave it a once over and adjusted the chain, didn't find anything else about to fall off.

[the voices]

well done on the swap tony, are you going to strip the old engine and have a look in ?

[tony22]

well done on the swap tony, are you going to strip the old engine and have a look in ?

When I changed the cam chain at 75k ish it was in very good condition, still wasn't burning hardly any oil between changes, will look out for a gearbox or output shaft to build it up as a spare and store in the garage just encase.