Topic: Engine rebuild questions, first timer.

[Elan]

So I jumped in on a first time rebuild yesterday on my k6 project. The initial plan was to change the gaskets, but it seems the pistons are a little loose so Im going to change them out(I tested by fitting a .005 shim between the piston and cylinder wall. according to haynes, if it fits, thats bad.)  I figure if I'm going to be boring out the cylinder, maybe i should go ahead with an 836cc. Anyway, Going ok so far, but have some questions.I know I should replace the cam chain and tensioner, but they look pretty good to me. Is it possible to measure the chain to see if it needs replacement? and as far as the tensioner, think I really need to replace it? heres a pic...


Now that the top end is off, Im ready to split the lower case. All covers are off. it looks like I only need to remove the points plate? or do I need to take out the clutch and shifting mechanism? and after all bolts are loosened, should the crankcase be upsidedown when splitting?

doesnt seem like I would need to remove these...



Lastly, know of any machinists in new england?

[mystic_1]

That tensioner looks to be in reasonable shape, check to make sure the rubber is still pliable and not hard-as-a-rock.

Not certain there a measurement spec for the cam chain, but they're relatively affordable so might want to change it just for peace-of-mind.  If the motor were together, you could retract the tensioner all the way and then see how far it moves when you release it onto the chain, that'll give you a rough idea how worn the chain is.

As to splitting the cases, by the book you remove the upper bolts and then flip the motor upside down, remove the lower bolts and lift the lower half off of the upper half.  You'll want to remove the shifter mechanism and the coutershaft bearing support, so that the mainshaft stays in the upper case when you lift the lower off.

mystic_1

[ekpent]

Take pictures and make good notes when taking off that shift mechanism. Can be a little daunting and confusing putting it back together for a first timer,especially if project gets delayed. 

[Skunk Stripe]

I second the pics and use a camera, not a cellphone. Better quality.

[Elan]

Yeah I was a little intimidated by the shift mechanism, but I've gotten this far... Will take lots of pics. Thanks guys!

[Elan]

Ok I know a digital caliper isnt the best for measuring this stuff, but It should give me a good idea of wear, right? this is what I have for one of my pistons. I just want to make sure I will in fact need to replace them(and not just rings or something like that). What do you guys think? they are measured front to back.