Polishing your parts

Polishing parts is a very good idea to save pieces that you might otherwise think are junk. This is especially helpful with internal engine components and hardware. I have been doing a few different techniques lately to restore the beauty in parts and I have found that nothing works better than a bench grinder that has dual wheels. One wheel is typically a graphite stone grinder (DON'T USE THIS SIDE! YOU WILL ACTUALLY TAKE METAL OFF AND THIN YOUR PARTS!) and the other wheel is a heavy duty wire polisher (the side we will be dealing with). This tool is an extremely expensive investment, so if you don't already have one, you might want to try and make friends with some one that does! Luckily, my step-father has one. I can't even begin to explain how well this method works. Last weekend I used it on my gear selector, my clutch cover, my piston, and my cylinder and some random hardware. These parts were rusty, grimy, and extremely dirty. Now they look like they just rolled off of the factory assembly line.

Today, I tried to use a dremel with wire grinding tips to polish some parts. I don't recommend this method at all except for maybe very mild use to get into crevasses that you can't reach with the bench grinder. It works pretty well, but little bits of wire fly off of the dremel bits until all of the wires are gone and you're left with nothing. And this isn't a slow process. I bought two bits this afternoon. Within an hour of usage, both bits were reduced to nothing. So, don't do this more than necessary. Because of little wire fragments flying everywhere, I would especially not use this method on internal engine components as an alternative to taking the parts out of the case and using a bench grinder. It is absolutely crucial that the inside of the engine is COMPLETELY free of debris when reassembling it. And this frankly can't be accomplished with all of those little bits of wire flying inside the case. Take the time to take out the individual pieces and use the bench grinder. Your engine will thank you.

You may be tempted to wire polish your casings. While this will look very nice, a lot of people don't recommend it. Jeremy's blog goes into detail about it, but simply put; the engine case will get dirty, and fast. If you don't want to clean your engine case every day of your life, don't set it up for these high standards. Media blasting or a good scrubbing with paint thinner is sufficient.

Ciao.

Engine tear down

Yesterday, I finally got the piston loose from the engine. I just decided to get out a hacksaw and cut the connecting rod in half. After that, one good whack on the sliced half of the rod connected to the piston got it un-seized. From what I can tell, the piston will be fine. But I will need new rings and a new connecting rod. The cylinder will be fine after a good cleaning.

After freeing the piston, I could finally finish splitting the engine case. I took a heat gun to the main bearing for a few seconds then lightly tapped the seem of the engine case with a rubber mallet and it started to slowly come apart. Then I realized the gear selector needed to come off. You may have noticed in my previous engine pictures, there was some sort of cement all over the gear selector. I guess the previous owner decided it was a good idea to do that instead of replace a gasket. Luckily, it all came off with a chisel and light hammer

taps. But the gear selector is so rusty that I might as well replace the whole thing.

I still don't have the tool to remove the clutch, so I got it as disassembled as I could and then just did a lot of cleaning with paint thinner and a wire brush and rags. You would really be surprised what a little bit of elbow grease can do to these old engines. You can really bring them back to looking just like new. And it really isn't hard work, in fact it's pretty relaxing. If you are doing a restoration, do yourself a favor and opt to rebuild your own engine instead of buying a new one or having some one else do the work. It is so rewarding to see how everything works and bring all the luster back into the heart of your scooter. When I split the case, there was rust, grime, sludge, and dirt everywhere (see pictures). I'm not done yet, I'll post pictures in the next few days of how clean it all is when it's ready to be put back together.

I can't get to the clutch assembly yet, so I can't tell if anything in there needs to be replaced. As far as I can tell, everything is alright. The bearings are even in pretty good shape. But I would still like to replace them. Does anybody have any tips for getting those suckers off? I can't get to the clutch side one yet, but I am having trouble with the crank side one.

That's all for now, be on the lookout for some clean engine photos in the next few days.

Ciao.