DJ2.1 Rebuild

[maxstu]

Hahaha! You guys.

As l said earlier. Some time in May, perhaps. When ALL the tappets are soft, no doubt.

No photos today....

Reset valves at one revolution plus a quarter turn from zero lash. Added four new spark plugs. Cleaned up the rocker covers and replaced the cork gaskets. And finally slipped them on cylinder heads with a smear of grease.

Engine now closed up.

Took a 30mm socket to the DJ pulley bolt and rotated the crank clockwise. Wow! The compression is phenomenal compared to a DG. It's like rotating the propeller on a Swopwith Camel.. Shooumper, shooumper, shooumper.

[Stesaw]

Well you know, someones gotta crack the whip
Youll be pleased when its all done stu

[maxstu]

Well you know, someones gotta crack the whip
Youll be pleased when its all done stu

I've a female at home doing that!

[Stesaw]

Well you know, someones gotta crack the whip
Youll be pleased when its all done stu

I've a female at home doing that!

You must be out of arms reach saying such things

[maxstu]

In a different room, Steve. Maxine has oodles of female intuition.

[maxstu]

Lost the thread with this rebuild. Mainly, now, due to bluetits nesting in a box by garage. So giving them extra space until fledglings bugger off.
While l thinking of it, fitting the PAS pulley question. Fit the bolt with or without washer?
One manual reads with. Another states without and only fit using a single groove pulley?

[ajsimmo]

Lost the thread with this rebuild. Mainly, now, due to bluetits nesting in a box by garage. So giving them extra space until fledglings bugger off.
While l thinking of it, fitting the PAS pulley question. Fit the bolt with or without washer?
One manual reads with. Another states without and only fit using a single groove pulley?

Single groove pulley - short bolt and big washer.
Three groove pulley - long bolt and no washer, laced up FT. And an extra O ring on the crank.

Sent from my moto g(30) using Tapatalk

[maxstu]

Lost the thread with this rebuild. Mainly, now, due to bluetits nesting in a box by garage. So giving them extra space until fledglings bugger off.
While l thinking of it, fitting the PAS pulley question. Fit the bolt with or without washer?
One manual reads with. Another states without and only fit using a single groove pulley?

Single groove pulley - short bolt and big washer.
Three groove pulley - long bolt and no washer, laced up FT. And an extra O ring on the crank.

Sent from my moto g(30) using Tapatalk

Thank you.

[maxstu]

The bluetits fledged late May. We saw only two chicks leave the nest box. Hopefully there were more. Then more time away from engine rebuild (and home) as we have decided to sell our stable yard after six years of seeking planning permission came to nowt. So having a massive tidy before going to equine agent.

Old engine out and starting the swap over of ancillaries.

Old 1.9 with Digijet.



Newly rebuilt 2.1. Can't wait to have the extra ponies under my right foot again.



Oil seal for dipstick question. Black hard-sided one pulled from old engine, but which one is the correct type?

Seal on left from gasket kit.

[maxstu]

Anyone care to answer my previous post, please?
Also, engine ready for install.



But another question.....

Ive fitted a Brickwerks oil switch relocator. Now on top of engine instead of between pushrod tubes. Yet the blue oil switch does not fully seat itself. Can l reduce (cut) the thread down, without harming the switch, so it sits snugly against it's washer?





Thank you
Stuart

[silverbullet]

The black hard plastic sleeve goes into the dipstick bore, the O ring sits on top of that and then the clip on the dipstick stay keeps the tube clamped down onto the O ring.

Can't comment on the switch relocation hose, I thought they were only used when you have a gauge sender which is much more bulky?

[R0B]

I have the yet to be fitted kit. And methinks you need one of these Stu.
https://brickwerks.co.uk/product/vdo-se ... bar-m10x1/

[maxstu]

Thanks to both for your replies...

My idea for using this relocator pipe is simply so l dont have to 'get under' when l use my oil pressure testing kit; my back is not as it used to be in my sixth decade. l thought it would work with a blue oil switch, as the pipe still carries oil to the switch? Perhaps with delayed reaction, though? Should l prime the pipe with oil before firing up rebuilt engine?

My neighbour, a mechanic, gave me this, in exchange for garage door new lifting wires l had stored away. A favourable deal, perhaps?
0-5bar..



The thread is tapered. So gently tighten until firm, l guess? Use PTFE tape?

Thanks
Stuart

[R0B]

You will also need to source one of these Stu.
https://brickwerks.co.uk/product/vdo-ga ... ure-5-bar/

[maxstu]

You will also need to source one of these Stu.
https://brickwerks.co.uk/product/vdo-ga ... ure-5-bar/

Okay. Hmmm? I think l will go back to standard set up for initial engine start/break in. I need to be certain dash oil light goes out on start up.