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81
The Thumper Years: Modified To Full Customs / Re: FT500 Vintage racer
« Last post by hellblom 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
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The Thumper Years: Modified To Full Customs / Re: FT500 Vintage racer
« Last post by FT500R 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..
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The Thumper Years: Modified To Full Customs / Re: FT500 Vintage racer
« Last post by FT500R 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  :-\
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The Thumper Years: Modified To Full Customs / Re: Revival Cycles Custom FT500 Ascot
« Last post by hellblom on January 31, 2021, 02:26:40 pm »
Here's them showing it on YT: https://www.youtube.com/watch?v=llw7vF0eYGw
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The Thumper Years: Modified To Full Customs / Re: FT500 Vintage racer
« Last post by murdo 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.
86
The Thumper Years: Modified To Full Customs / Re: FT500 Vintage racer
« Last post by FT500R on January 30, 2021, 03:01:24 pm »
Managed to get the camchaintensioner bolt that was stripped out by prying a flathead screwdriver between the camchaintensioner and the cilinder head on the inside. This put enough pressure on the bolt for the threads to bite and to screw out.
Removing the head was peanuts afterwards (helps that the lower two head nuts were missing.)
The valves and piston are not completely covered in carbon build up which is a good thing. A not so good thing is the piece of helicoil sticking out of the sparkplug hole.
The used head gasket is aftermarket so again an indication someone messed with the bike before (and did not do a good job).
87
The Thumper Years: Modified To Full Customs / Re: FT500 Vintage racer
« Last post by FT500R on January 29, 2021, 05:41:42 am »
I power washed the engine and started taking it apart to freshen it up.

I found a lot of non- standard bolts and RTV which is never a good sign. Someone has been in this engine before and he/she was not gentle.
Will probably have to helicoil every headcover bolt (standard practice with the FT anyway) and replace all of those bolts as the threads have gone on those too.
Unfortunately the rockerarms have completely worn so I will have to replace those. I was afraid the cam was a goner too but after comparing it with a spare one, which I know is good, it turns out this one is not that bad either. After measuring the camshaft journals and even the lobe height are well within spec.
The camchaintensioner bolt is loose but won't come out so I suspect the same problem one of the other members of the ascot facebook board had. I also discovered that the 2 head nuts on the underside of the head are missing... Pretty amazing what you find on a 150 euro 40 year old bike
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The Thumper Years: Modified To Full Customs / Re: FT500 Vintage racer
« Last post by murdo on January 26, 2021, 07:02:51 pm »
Very nice.
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The Thumper Years: Modified To Full Customs / Re: FT500 Vintage racer
« Last post by hellblom on January 26, 2021, 08:01:49 am »
Cozy shed you got!
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The Thumper Years: Modified To Full Customs / Re: FT500 Vintage racer
« Last post by FT500R on January 25, 2021, 07:51:22 am »
Completely moved now and very happen with my new little shed.
I thought I would have a lot less room but actually I am able to fit both FTs inside where before I could only fit 1.

Now both bikes are inside I can start freshing up the engine of the race FT.

I started draining the oil and there was a lot of sludge in there, even though I renewed the oil 2 months ago and the bike didn't run in between. I think some rain water leaked in the breather while the bike was outside.

Half an hour later I had the engine out.
Next step is to cover all openings and power wash the engine. When it is clean I'll probably whip up a small engine stand to have the engine more stable and upright.
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