World tour.

The FedEx tracking shows my box left Freisling, Germany and stopped in Paris, Guangzhou, Singapore before arriving in Sydney, it's now on it's way to Melbourne and eventually to me, they estimate the 27th, but I'm fairly confident that it will be here before then, hopefully on the 25th, so I can spend the Australia Day public holiday getting it all back together, as well as having a barby with prawns and lamb chops, drinking beer in my bluey and stubbies and watching cricket, but that goes without saying.
In the meantime, on the tinkering front......

I've been cleaning, replacing some hardware and a few other things.
Pictures are:
1 - new and old screw for securing the arr box to the case.
2 - where the airbox sits looks like it has been ever so gently shaped with a bastard file.
3 - I had to dremel out the hole to accommodate the new screw, not with a surgeons precision but it's functional.
4 - The old trunnion is what was holding the end of the throttle cable to the arm on the carb. the shiny new one will be relieving it of its duty.
5 - The choke handle has seen better days as had the choke cable inner and outer, the handle will stay but the cables have been replaced.

Waiting game.

The FedEx tracking service tells me the 25th so I'm just sitting tight and finding something to do,  The carb will come off and I'll clean up the airbox etc.

Cases are together, oil in, stator on and reset 3 degrees closer to TDC. I am going to have another look at the front brake and the horn to see if I can't get them right too.

Otherwise.......

When I was cleaning I noticed that what I first thought was just a line of dirt where the cowl rubber sat, was actually a groove worn into the paint, speaks volumes for the quality of the paint when rubber can wear a line through it in twelve or so months.

Getting to know you.

My first box of parts arrived today, so it's back to re-assembling the engine, the last couple of days has been spent just cleaning in the areas that are normally harder to get to., I have given the cases a good clean out as well, and I was surprised of how much general crap there was considering it should only be oil and the material that comes from metal wearing. I have since examined everything closer and found signs of wear that I am guessing would be normal but leaving the components still serviceable.
I'm not ready to go down the road of a full engine rebuild, the crank should probably be replaced and the con rod has a bush in the end where a caged needle bearing should be, confirming what some people have questioned in the past that some, or maybe more, of the engine is from a -----.
I don't have the funds to proceed with dropping the engine and overhauling what's left, I pushed the friendship with the wife spending on parts for this engine work as it is, the thing is I also don't want the scooter just sitting there in bits looking at me wondering when I was going to be riding it again.
This decision may have already made for me depending on how it all goes back together, a few days will tell.
Some pictures.

First three are just comparison between parts.
Four is the wear caused by the worn kick start gear.
The last is the collection of case nuts next to a new one, I omitted the 3075 washers, I used new washers, lock washers and nuts all round.
Last night I put the new kickstart components in and carefully installed the new case gasket with gasket cement, now I had a gasket set I was certain was a three port, that's what I ordered, over a year ago and it wasn't until recently I discovered it was a for a two port, so I needed to change it a little so it would fit, just cut the top of it to allow for the third port and one bolt hole that was about an inch or so from where it should be, no dramas.
The case went back together no problems, next was the gears selector gasket and I greased up the gear selector and put it back on, I then hooked up the gear cables and roughly located them and called it a night.
Next up will be the stator, it was set at 22 degrees BTDC, the kit, a DR177, is recommended to be set at or around 19 degrees, I'll hook the wiring back up and hopefully the kit arrives by the end of the week.

Gear box

Much to my surprise, the gearbox was in pretty good condition, the cruciform wasn't worn, all the gears were in good condition, the only downside to my untrained eyes was the plate at the back of the christmas tree had some surface rust and was obviously old and the case stud in the bottom picture is held in by some sort of liquid nail type substance. All in all I was happy with what I could see, so I cleaned it up and once the new parts arrive I'll put it all back together, I'm guessing that all my parts and the new kit,  the new 24/24 carb and the few odds and ends will be here by next weekend, In the mean time I will be giving Gloria a good once over service and a wash. 

A good result all round, cue sigh of relief.

One thing I noticed while pulling the case apart was the amount of washers the guys used and have used on other parts of the scooters, literally hundreds and the quality couldn't be lower, they are paper thin which is probably why they use so many.....

Kickstart

Next cab off the rank, the kickstart set up.

Top photo is the chip off one of the teeth, must have happened before I got the scooter as I would assume that I'd either find it in the case or it would've been chewed up by the gears or worse....anyway, none of that happened, it will be replaced anyway.

Second one is the rubber stopper worn to within an inch of its life, I flicked the opposite one in pic three to show what it should've looked like, they are both old and hard as rocks, replacing these too.

Finally the starter gear, it is a little worn and most likely the cause of the kick start slipping, it's on the list too,

Gear Selector

I started off by draining the oil, it was 950kms old and the usual grey colour, a few very small flecks of metal, normal stuff, I dropped the exhaust and pulled the cylinder head and barrel off, I noticed there was little resistance from the head nuts and there was some fuel/ oil kind of leaking from the head, this explained the most likely reason the bike was running ok but progressively getting harder to start was the lack of compression, not helped by me flogging the old girl the other week to see just how fast I could go
Since I cleaned it up last time, there was evidence that the rings just weren't doing their job, there was dark marks down the sides, out of interest I changed the old rings for the third oversize ones I had, the gap was a hell of a lot bigger than the maximum .35 the manual suggested. My decision was made for me. I ordered a new cylinder kit and it's on its way, I'll go more into the kit later.
I put the piston, cylinder, rings and head in a bag and put it on a shelf, I realise I could've just re-torqued the nuts and it would've been ok, but another bandaid wasn't going to fix it for ever.
So on to the gear selector, I took the kick start lever off, it was old and worn as expected, the spline was still in ok condition so it will go back on later. after I cleaned all the grease and crud off it, it's tyre colours began to shine, it would appear the tool of choice was an angle grinder and things are a little bent out of shape, nothing a hit with the dremmel won't fix, it is still solid, moves true and firmly, this too will get a good greasing and be put back on.

The final frontier.

I think the GPS speed trial did nothing for the engine on the Sprint V, everyday since starting the engine got harder and she went from a 2-3 kick bike to a wont start at all bike and the kick start was slipping more and more
A perfect excuse to fix something, I sat in the workshop last night after I built a small ramp to get the scooter in over the door step....I think it's time.
I am slightly nervous about splitting the cases, but also excited. A little concerned that I will find some more dodgey shit as well.
So I made a plan.
Pull the head and cylinder off and replace it with a new kit.
Pull the gear selector off and clean it up.
Split the cases and replace the kick start internals regardless of condition, have a really good look at the rest and see where I go from there. I'll replace the hardware as I go, the cruciform as well and with the kit I will need to alter the timing so I can give the stator an overhaul, check the points gap etc. As long as all is ok that's as far as I will go, time will tell.