In the last update, I had completed the work of putting the crankcase back together and was considering re-mounting it in the frame before completing the rest of the reassembly. Of course, there was some frame painting that I wanted to do first and wasn’t getting to, so I finally went ahead with completing the re-build of the engine in the basement. Glad it worked out this way since it would have most likely made things more difficult to work with the confines of the engine in the frame and lower to the ground.
Next up was to reinstall the four pistons and get them reinserted to the cylinder block. Reinstalling the pistons to the connecting rods is pretty straightforward, just reinstalling the circlip to keep the wrist pin in place. Definitely want to block the hole below the piston while doing this. It would be a traumatic experience if you just completed reconstructing the crankcase and then dropped the circlip into the bowels of the crankcase.
Place the o-rings on each cylinder and the gasket on the crankcase and you are ready to go to reinstall the cylinders.
I started with the number 2 and 3 pistons thinking it would be easier to work on those with as much room as possible. Ring compressors were added to those two pistons and the cylinders lowered on to the pistons.
With those two installed, it gets a bit more fun trying to rotate the crank enough to raise the 1 and 4 pistons up while not losing connection to the 2 and 3 pistons.
And that is it.
I do have to admit to a few oversights in this process. First, the whole reason for the engine rebuild was to replace the broken rear cam chain guide. The first time I lowered the cylinders on to the 2 and 3 pistons I failed to make sure that the cam guide was in the cam chain tunnel. Cylinders back off. The next time, the 2 and 3 pistons pulled back out while trying to get the 1 and 4 pistons to rotate in. The third time I did everything very quickly, but then wondered why the cylinder was such a sloppy fit and realized I had left out the two locating pins between the crankcase and the cylinders. Fourth time was a charm and I am now a master at getting the pistons inserted to the cylinders…