Saturday we (Myself and Zonie (Norton John)) tackled the valve train of the W650. Amazingly, we found the threads in the head were fine, so the only parts I used from the head and gear case I bought were the shims for the bevel gear. The used head I bought turned out to be a wonderful training aid on how to assemble/disassemble the valve train components and a practice tool for the real thing. So, after discovering the head was ok, I was pretty happy. Of course, I bought all of the tools to work on the valve train components and they actually helped immensely ($400 for factory tools, costly, but worth it to do the job right).
So, I started by trying to clean up the used head so I could get ready to swap. Then I decided to build out the gear case so I could then focus on the head. Basically, the bevel gear rides in a bearing. The bearing gets spacers to set the lash (the spec is 0.0 in) which is pretty easy to achieve if there are enough shims. I had a few extra because I had two gear cases. So I shimmed it and torqued the bolts.
By the way, machined surfaces are very very sharp. I cut myself twice in the same wound! Trying to push the bearing carrier out to swap spacers a time or two. The second one was pretty messy.
The whole job took a toll on Mr. Band Aid. Yes, afterwards, I cleaned it with soap and water, did the Hydrogen Peroxide thing and added anti-bacterial ointment. I then put a new Band Aid on her. All good. P.S. That is grease and oil and not much dried blood...
I used the adjuster and a 32mm wrench to thread the bearing carrier into the head. It was slightly tougher than the fingers could grip but very smooth and easy. Zonie snapped a couple of pics of the event. Looks pretty serious. Then we messed with the threads in the head. I found that once I pushed through the o-ring the threads were perfectly smooth.
All set
Putting the gear case on and aligning the gears and shaft was a touch fiddly, first we get TDC
Made sure the cam was at TDC as well.
Then I verified the gaskets are all there, the dowel/plunger is there, and in the oval shaped gasket hole the oil nozzle is installed, then I put her on.
Then I had to put the gear over the crank gear, wiggle the shaft around, go check the timing and then I had to hold the shaft in the upper gear, slide in the c-clip and then raise the tube, insert the o-rings into the upper part, install that clip and I was done.
Now hopefully she won't leak, I need a few minor parts and I want to put bigger jets in the carbs so we have a touch more oomph on top. Also, I may go up one on the pilots and shim the needles, but the jury is out on that. I will probably leave it for the winter and then set it up in the spring.
So, the most important thing, was John came by and helped me out. I lost my will to work on it a couple of times and he kept encouraging me. I think if he hadn't come over, I would never have gotten this installed. Always important to have friends who support you. Thank You John, you the man. Then, I booger-welded a fender tab for him. He said. "Don't worry I can grind that off, no big deal"
Again, always good to have friends. Hopefully, I will get the little bike running in a day or so and see if she purrs or if we have issues. I expect the purring will occur. On a light note (pun intended) I discovered we have a lithium Fe battery in the W650. I am glad of that. She also has a new left side airbox to install and I have figured out the magical throttle cable removal sequence that makes it simple and easy. So, when I get some more parts, as if I don't have enough now, I will put her the rest of the way together. I may pop up to the dentless repair folks and see if they can knock the dent out of my tank. We shall see.
Merry Christmas to you and yours.
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