Another 390 Auto Engine

[grouty]

After the overheating issues with the last motor, I thought I would put together another to test my theory ! Most of the bottom end is NOS. A pair of NOS crankcases thanks to Steve (Stormer 254). A NOS crank, new rod and piston. The barrel and head came from my stock. The barrel went to 2nd oversize at 83.5 and with a new Kawasaki small end bearing it all started again.

The black paint is a secret coating from Rod Spry Restorations here in the UK.

All bearings are new ...

 

[stormer254]

That puts my 'rebuilds' to shame!

 

[oldbikedude]

Isn't it more of a just a "Build" ....lol

 

[grouty]

Thought I would try a set of these reeds ...

This engine is getting a different ignition system from the last one. For the Power Dynamo system I had to go and find the Motoplat back plate.

 

[suprize]

for the art cabinet??

 

[stormer254]

The garage alone looks like an art cabinet compared to my s### pit!!

 

[grouty]

Trust me Steve ..... all is not as it seems. They are carefully aimed shots, with the occasional "background" tidy up

 

[Laverdaton]

Where are you in the UK? I live in Gloucester.

 

[grouty]

I'm down in Devon, between Exeter and Plymouth.

 

[grouty]

The previous picture shows the Motoplat back plate loctited in position. I am fitting the Power Dynamo system this time. This unit uses the existing plate unlike the Electrex one that has it's own. The stator is then fitted to this and the screws loctited. As it has no key way I don't see the point in having it adjustable.

 

[grouty]

Engine is timed and the flywheel carefully lined up. Then checked several times ! Nut is then just nipped up until it's back in the frame to hold it steady while I tighten it.

Timing is set to 1.9mm BTDC

 

[grouty]

Gearbox from the other engine back in. First gear lapped to the new crank. Not sure what happened when I took the picture, but it's a bit blurred.

Probably one of the most important additions is the spring saver (or should that be case saver !)

Just the nut to put on and nip up. Final tightening will be done with the engine back in the frame.

Kickstart cover assembled and kick lever timed up nicely. Super easy job.

 

[grouty]

Fitting the coil, and regulator rectifier was a small pain. The coil is slightly larger than the Electrex one, and there was no way the reg/rectifier was going to fit. It is a strange shape that means if the wires one side clear the inside of the tank tunnel, the mounting bolt the other side fouls it ! Probably a few hours riding would see it rub into the steel !!
Just a bit of tidying to do here on the wires, then tank on.

The only place I could think of hiding the R/R was under the seat. Two 40mm P clips worked a treat. Bit of a pain cutting off the nice premade wiring plugs, but it has to be done. Wires extended and an earth wire attached.

 

[grouty]

It started really easy after a couple of prods. A quick trip up the road to check all is working. I now even have a working horn ! Something that for some reason the Electrex would not do. Took it for it's MOT on Sat, and then a trip a few miles down the road to see a mate for a cup of tea or two.

It looked nice sat on his drive, so I couldn't resist taking a couple of pictures. The trip back was uneventful with no signs of overheating in the traffic.

So far ..... So happy

 

[suprize]

nice.....very nice

 

[Michel Dufayard]

Who is Igor ?

 

[oldbikedude]

Real nice work.

 

[suprize]

Igor was helping the "master" heh heh hhhh

 

[DPete]

Beautiful work, I'm curious as to how the trans shifts, any chance of a quick explanation, I understand the clutch.

 

[stormer254]

Black magic