Haven't made any progress on the frozen engine. Found out the cylinder is still full of oil from the PO trying to free it up. I think I'll just do a teardown anyway to check everything out. It may wait until winter, too much going on now.
I did manage to get the fuel tank cleaned out pretty well. The PO let it set with a full tank of fuel for 30 or so years, so all that was left was the sludge. I decided to try a tank full of E85, since the it's pretty potent stuff I figured it would clean out the remaining sludge. I let it sit in the tank for a couple of weeks, rattling a bunch of large nuts around in it every so often, then drained it (looked like muddy water) and flushed with gas. I need to get a mirror in there, but what I can see looks like new except for some minor surface rust in the very bottom. I think the sludge protected the tank from moisture.
Swap meet find- 67 Scrambler restoreTime has been at a premium lately. I managed to spend a couple hours and pulled the right side cover off and the coils so the rotor was out in the open. I put my metal strap type oil filter wrench on it was able to put a little more pressure on it than I was willing to put on the bolt. Whoppee!!! It broke free and the force I used wasn't all that great. Right now it only turns about 1/8 to 1/4 turn, but that's enough. I'm going to pull it apart anyway. I figure after sitting 30+ years there is no point in taking a chance on a lot of gunk jamming things up. When I pulled the air filters and hoses, on one filter the paper crumbled, the other hose was just barely on the carburator and there was plenty of dust in both of them. My guess is that it will need a bore job in any case. I also need to pull the left side off as well and see why it won't shift. I really don't see any point in not splitting the cases and checking everything out anyway. A new set of seals will probably save headaches later on as well.
63 CA78
Pulled the engine yesterday. A come-along and a couple of lift straps worked well. Pulling the left exhaust studs helped. I was surprised they came out so easily. I drained the oil, no water in the bottom (althought the oil was a bit thick and black as tar.) It's now upside down, draining the oil put in the cylinder to free it up. Next up, getting to the heart of the machine.
63 CA78
Tried to resize some pictures but with no success, not on my usual computer. Maybe I'll be able to add them later.
Pulled the engine apart. Only one stripped bolt hole, no broken bolts. The one cylinder was UGLY, full of muck (from the oil soaking it for a long time) and rust. I managed to get it down enough to pull the wrist pin and lift the barrel off. I wire brushed the bore and pounded the piston out the top. The rust pits were so bad in the cylinder that it can't be rebored, and it was standard! The other cylinder will take a bore, so I have a NOS coming from eBay to replace the bad one. The old one came out pretty well once I got it warmed up to about 200 degrees, or a little more. Infrared thermometer came in handy. The engine and transmission were full of almost jell-like sticky goo. The transmission wouldn't shift because it was glued in place by this stuff. Degreaser wouldn't hardly touch it, so I soaked the parts in E85 for about a week and everything cleaned up pretty good. Very little rust. The brass bushing is nearly gone. The only other problem with the engine/transmission assembly is the kickstart shaft has about a half spline twist in the splines. Someone got a little too forceful while the engine was frozen. Question is, will it last? The shaft otherwise is in excellent condition.
Last edited by OldStan on Wed Oct 30, 2013 9:30 am, edited 1 time in total.
63 CA78
When there is a twixt at the splines the shaft is destroyed and I recommend you replace it.
What does the KS pawl look like?. ..................lm.
Not a good day. Picked up a NOS sleeve on eBay. I had no problem getting the old sleeve out, cleaned the sleeve, froze it overnight, heated the barrel assembly up and started to put it in. It should have slid in easily, but it barely got started. The other sleeve slipped out, i had to put it back in. I knocked the new sleeve back out, let it cool and measured it. The OD is about .005 inch larger than the old one. Hadn't thought to measure that, had compared everything else. It wasn't advertised as oversize, didn't even realize they existed. I guess I have two choices, get the barrel bored oversize for the sleeve or find another sleeve.
63 CA78
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