PP's GSX-R 7/11 Engine - Part 4

With the valves done, the main chunk of the work has been completed - at least that's what I thought, the cams went back in place, and this is where the engine really started fighting back.

The cam retaining guides needed some helicoiling, there was some sort of "Instant Gasket" over most of the surfaces which needed cleaning, bolts were missing, there was no timing guide as well as a host of other little niggles that have been discovered.

With the cams slotted into place we needed to time them in. Big problem though, the Dyna2000 kit that I intend to use in this engine has no timing marks on it. Fortunately, Rich works alongside a bloke who uses a 1052 motor in his drag-bike and he just happened to still have the necessary parts lying around.

We fitted an Orient Express manual cam-chain adjuster (supplied by Big CC Racing), as the standard ones are known to become a bit troublesome after a few years. Timing the cams couldn't be simpler, just follow the instructions in the Haynes Manual and job done in about 10 minutes. The tappets needed to be checked, as all valves had been ground in, we were expecting them all to be on the tight side. Oddly enough, most of them were quite close within the limits specified. This engine must have rattled like a baby's dummy when it was last run! It doesn't take long to adjust the tappets and it's definitely an easy job for someone who can read a set of feeler-gauges.

Then it came to putting the rocker cover on and sealing the engine. I'd obtained some BSR cam bolts, not sure where from, but they were still in the pack so I thought it'd be a shame not to use them. All but one of these went in, so the rocker cover had to be removed and a new thread tapped to allow the bolt to screw down. It was a bit of a mystery because the standard bolt fits fine, but the BSR one didn't - all we canassume is that the retainer must be on the minimum tolerance and the bolt's screw thread on the maximum.

Still, engine closed and ready to go into the frame - very exciting moments coming up.