The other ER5 restoration .

[fastbob]

An hour and a can of Vimto later and I've got a pristine jointing surface . I could have this engine back together by Sunday .

Edited October 15, 2020 by fastbob

[Bender]

Was the Vimto for you or the engine.

[fastbob]

So I've just cleaned up this barrel and pistons that I bought off eBay for £32.00 . It's in absolutely brilliant condition and I'm delighted with it . So I Googled Cradley Kawasaki and added up the cost new of everything in this picture excluding the dowels and circlips . £ 1,370.01

[Old-codger]

Nice job Bob are you going to spray the barrels before you fit them or are they good enough already.

[fastbob]

Nice job Bob are you going to spray the barrels before you fit them or are they good enough already.

 

Beautiful condition inside and out so no paint required .

[fastbob]

Crankcase painted .

[Mickly]

Crankcase painted .

 

[mention]fastbob[/mention] what do you use to paint crank cases?

I used Simoniz tough black with Halfords petrol resistant laquer, as soon as a bit of petrol leaked (from a loose carb drain screw & a hose joint) on to them it all crinckled and peeled off

[Old-codger]

I dont know how Halfords get away with selling that crap petrol resistant lacquer in no way is it resistant. form a mile away if you waved a petrol stained rag in its direction the lacquer peels off It is rubbish.

[fastbob]

Crankcase painted .

 

@fastbob what do you use to paint crank cases?

I used Simoniz tough black with Halfords petrol resistant laquer, as soon as a bit of petrol leaked (from a loose carb drain screw & a hose joint) on to them it all crinckled and peeled off

 

It's Halfords VHT Metallic Black . I'm going to leave it for 24 hrs and then give it a going over with a heat gun . It's a bit of an experiment so we'll see .

[Mickly]

I dont know how Halfords get away with selling that crap petrol resistant lacquer in no way is it resistant. form a mile away if you waved a petrol stained rag in its direction the lacquer peels off It is rubbish.

 

Add to that Simoniz high temperature satin black paint on exhaust headers, allegedly good up to 800 degrees C, started up the Trophy, the paint gave off some noxious gases, I thought “ok it’s curing” after 5 mins the smoke died down & left me with flaking paint & a white discolouration!! Absolute shite !!

[fastbob]

Mmmm , shiny pistons .

[fastbob]

And that's how we do that ! Always a bit nerve racking inserting pistons into bores but the ER5 is a joy to work on . The liners have a really wide and shallow taper which practically compresses the rings for you so it's almost a case of just setting it all up and letting gravity do the work . Little things please little minds and I'm f*****g ecstatic ! This is usually when you find that the base gasket is still in the packet .

[James in Brum]

Must say I find your work inspiring Bob.

[fastbob]

Looking like an engine again . Camshafts and timing tomorrow .

[fastbob]

Starter motor in . I deliberately left the alternator cover on during all the work so far to shield the magnetic rotor from ferrous particles. I didn't get the camshafts in this evening as planned because the alternator cover gasket took ages to remove . That's been a feature of this build . All the gaskets have been absolutely rock hard and seemingly baked onto the mating surfaces . Cellulose Thinners seems to have some softening effect but it's been very hard work carefully scraping them off .

[fastbob]

I'm ok using Rattle Cans but I can't seem to find a suitable Clear Coat that is petrol resistant .

 

C'mon bob it's easy..

https://www.halfords.com/motoring/paints-and-body-repair/specialist-and-decorative-paints/halfords-petrol-resistant-lacquer-300ml-768697.html

Also, just because I'm posting, I wouldn't bother taking the barrels off. It picks up well from idle, the rattles go away, you don't seem to be choking on smoke.. There can't be much wrong with that!

 

Oh yeah ?

[fastbob]

Oh yes ! Sixteen out of sixteen and not a stripped thread in sight . And yes , I used my smaller Torque Wrench at 12 nm which is about half a turn past finger tight . Finally I can put the Helicoil Kit away . Ok , it's only a cylinder head and there are plenty more on eBay but nonetheless it still gets the heart racing . I love spannerin' me .

[fastbob]

I knew that Harley lift would come in handy .

[fastbob]

Just the exhaust and a lot of fettling to do and that's that . Winter project done and the clocks haven't gone back yet .

[S-Westerly]

Looks bloody good, especially compared with what it was looking like when you got it. Well done you.

[dynax]

Time to start hunting for another project then

looking good though

[KiwiBob]

Time to start hunting for another project then

looking good though

 

At the speed this man works he will have next summers project done by this Christmas!

[JRH]

Good work [mention]fastbob[/mention]

[Guest]

Top job!

[skyrider]

yep it looks very smart