Piston + cylinder put on

We had to source the head gasket for 400cc which is discontinued; Kalina Industries from Zlín helped a great deal and manufactured an affordable replica from their portfolio. A broad variety of manufacturing machines and a great customer experience. Highly recommended.

Wössner piston set with gudgeon pin and piston rings seats ok with

an adequate clearance

OEM cylinder gasket and Oring

Installation with lubricated barrel and rings pressed inwards went rather smoothly

Moving

Big day in fact, the chassis has left the warmth of living room after few years for its journey to an engine transplantation. More about this logistic problem below.

Ok, this is the crankcase mounted in the bottom cradle; the engine is hanged from above by a gudgeon pin, otherwise it would have flipped forward. The key to this ingenious suspension actually is a norwegian wooden block.

Well, if you work on the chassis in the first floor, you will eventually face the issue how to fit it with the engine that is being completed in the garage...hm, then the funny things occur and the maiden voyage rather reminds of a trial bike session 

Staged comfortably

..to be continued

Crankcase assy

Here is the latest batch, the crankcase assy with internals: transmission, balancing shaft, shift cam assembly, etc, etc. The crankshaft goes super smoothly. 

08/27/18

 A small update - (a newbie in a garage - the bandit 1200 s keeps me on the road all my spare time - but who can really wonder, it is summer and if you've ever tasted the genuine 80's gsx-r massive-torqued four, no need to explain further) - actually only new is the bearing of the crankcase. While the bearing on the right side was replaced with a new SKF a while ago, the one on the left side is in fact a hard one. It can only be purchased as an OEM part from Yamaha together with a whole half of a crankshaft segment. But, the Oulehla Motor Parts workshop based near the picturesque town of Sternberk helped once again and the genuine bearing was taken off together with a drive gear of the timing chain after heating and replaced with the new Koyo bearing of a proper dimension, so the new costly OEM part wasn't eventually needed. It also might be worth mentioning that 600cc srx has both crankshaft bearings of the same diameter while the bearings on "400" differ.                

Now the engine parts are pretty much gathered and the assembly may commence.

Cylinder head coating

The last batch of painting with engine enamel: the cylinder head and valve cover. Since the day was partly cloudy, the 500W lamp helped to cope with show through. The emanated heat was so intense that the paint was almost backed at the same time :)

The whole barrel reminds me of LS 650. A nice lump for 400cc

And today..

I ran out of the black :) (what a great series of a days) 

Second batch

                        Baking at the laboratory of the utility muffin research kitchen

                                    Both halves of the cranckcase mounted together

 Respect to my dad for a skillful covering of all the connections, contact surfaces, etc. with the tape. Just amazing preparation

Primer

Black gloss applied

                                              and a bit more shiny clear coat (below)

What actually preceded this was the installation of bearings in the early springtime

Engine enamel

This is the latest update from today, coating with VHT baking finish. I tried only on the barrel since there has been a delay with this job as the first delivery of the primer was indurated and the cans were claimed (twice). It took the american producer more than one month to sort the claim and send a new batch to the distributor in Czechia. Anyway, the result is pretty good, looking forward for that baking (90°C for one hour duration) and subsequent clear coating.     

After finishing the coating, rubbing down the paint from the polished fins took approx. 3-4 hours, using cloth with a thinner

Last weekend

Smoothening the surface 

Almost ready for a final paint job

The cylinder head assembly, just a check with polished parts, chromed screws and new studs

The engine wil be coated with black gloss, soon