Author Topic: FT500 Vintage racer  (Read 4063 times)

murdo

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Re: FT500 Vintage racer
« Reply #50 on: January 30, 2021, 06:09:52 pm »
I share your grief about the sparkplug helicoil. I have successfully repaired them using a solid insert (timesert, nutsert, etc) with good results.

FT500R

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Re: FT500 Vintage racer
« Reply #51 on: January 31, 2021, 03:21:24 pm »
That's my plan to.
I'm looking into solid inserts that have small collar and thread in from the inside so it definitely won't come out when I remove the spark plug.

A bit more bad news today however. I don't know exactly what happened here but the piston is shot. The grooves in the cilinder wall are visible but I can't feel them. Hope to get them out after a hone and an one size over piston.
Starting to become a full engine overhaul  :-\

FT500R

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Re: FT500 Vintage racer
« Reply #52 on: February 05, 2021, 11:06:18 am »
Ordered a new piston.
I am also looking at buying a new second hand crank. Unfortunately the small end of mine is a bit pitted too.

Will do the valve stem seals this weekend, hope that I do not encounter too many other broken bits as this 'engine fresh-up' is starting to look like a complete rebuild pretty fast..

hellblom

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Re: FT500 Vintage racer
« Reply #53 on: February 09, 2021, 03:42:00 pm »
Wow, how unfortunate! I hope you will overcome all your issues. I also ordered a new piston, a Wiseco 10,5:1, so a little more compression.

Olle

FT500R

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Re: FT500 Vintage racer
« Reply #54 on: February 15, 2021, 04:30:56 am »
And the saga continues.
Cleaned up the inside of the head as much as possible and reground the valves.
The (inner) valve springs are out of spec so I have to start searching for new ones there. Any leads would be greatly appreciated.
I've used a copper wire wheel on some parts of the engine and it gets the paint of reasonably well. Decided that I will go for that look for the complete engine apart from the cilinder and head. I will not be able to get into the cooling fins so will paint those parts black.
I am also struggling with the rockercover shaft dowel. I got 1 out using the 'yahoo' method with tapping a thread on it and using that to pull itself out. The other one stripped the newly made threads unfortunately. I then tried the 'haynes' method by grinding a slot and trying to tap it out but as you can see that only bend the dowel.
Any thoughts or tips on this?
I also checked all the headcover bolt holes and it looks like I have to helicoil almost all of them (already anticipated that) strangely enough 1 bolt was M8, 1 was M7 and the rest appears to be M6 (although some stripped). The M8 and M7 do not correspond to the expected M7 bolts though.

murdo

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Re: FT500 Vintage racer
« Reply #55 on: February 15, 2021, 03:38:47 pm »
When I have had trouble with the dowels I welded an extra piece of steel to the dowel so as to be able to get a better grip on it with a vice. Cut off and cleaned up the dowel before returning to valve cover.

FT500R

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Re: FT500 Vintage racer
« Reply #56 on: February 18, 2021, 03:11:33 am »
Will try to weld a bolt or nut to the dowel.
I only have a 220v flux core mig welder so hope I can get enough heat in the dowel to make something stick to it.
I'll probably get a new dowel afterwards ;)

FT500R

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Re: FT500 Vintage racer
« Reply #57 on: February 24, 2021, 02:27:15 am »
Since the small end of my crank was damaged I bought a second hand one via Ebay.
Always a bit of a gamble but the one I received is in immaculate condition!
Very happy with that.
Continuing to strip the engine down to really get a proper overview of what I need to order.
I also got my new piston in (.5 oversize) so can send the cylinder out for a bore and a hone.

hellblom

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Re: FT500 Vintage racer
« Reply #58 on: February 25, 2021, 02:11:30 pm »
Good job!