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I forgot to include pictures. To be honest I didn't take any pics of the assembly process as I just wanted to get it done. So here's some take apart pics...


Engine in the frame with the valve inspection cover removed. As you can just barely see it's a push rod engine. The means the cam is located in the bottom end and the valves are activated by levers that are pushed up by the rods on the far side of the engine.


Cylinder head, with one valve partially removed.


Here's the cylinder head removed. All that black stuff is built up carbon - these are safety council bikes so they spend forever idling, and never hit highway speeds. That was burned on black crap about 1/5" thick that I had to literally chip off. Remember to wind your bike out a bit sometimes.


Label everything explicitly.


Valve parts.


Exhaust valve that's carboned to HELL!


Here you see the underside of the rocker arms. Those worn pad looking things are what ride on the camshaft. As the cam passes they are lifted up and push a rod that activates the valve at the top of the engine.


Yes, I actually did all the work.


Here's the clutch


Here's the insides of a clutch.

purry snazzy there Sev... do you take pics before ripping things apart as well, I was told that its a pretty good way to get an Idea how it should look afterwards... (especially wiring and what not)

[quote="Sev"]






Yes, I actually did all the work.





Is that you??

I feel your pain on the dowel pins. I did the first major mechanical work on my bike today. Rejetted the carb and removed/bypassed the PAIR valve... As soon as I got it done and all back together, I realized I should probably try to start it up... Lo and behold, after about 5 minutes of cranking it didn't work. I tried everything, but ended up rebuilding the carb again and finally it worked! I was at it from about 9 this morning to about 3 this afternoon... UGH it can suck to work like that! lol
Wrider

Piston should look like this...



Got it into the frame today, and other parts bolted on. Hopefully I'll get it started and running tomorrow.

Sev wrote:

Wow Sev - the 599 looks a lot different from what I remember.

Wiseass.

Dohun wrote:

Sev wrote: "picture of Sev wrecking a Safety Council bike"

Is that you??

This from Dohun who seems to think (well, maybe we've corrected him now) that all the members of TMW are guys or old guys or something like that ....can't remember his exact words... (and no offense all you great guys on here!)

Dohun wrote:Is that you??

No.

Sooo, school is almost done. Tomorrow is shop clean up. Thursday is the final exam for the second semester. And Friday is the apprenticeship exam. What am I most concerned about? The cleanup, I hate cleaning up.

Apparently the apprenticeship is so easy that guys who couldn't change a tire were getting 70's. Kind of scary when you consider they're working on your bike.

Friday after the test I'm rolling on out of here. Six hours to get home and do all that unpacking Jazz. Sat you'll find me out on the driveway doing the final adjustments to my bike to get it ready for the road. Malice plans on dropping by so we'll do a full service on his ride and see what happens.

Then... I'm going for a ride !