“Good news everyone!” The RGV’s engine officially works. The reinstallation of the engine took far longer than planned. That was due to a combination of intentional stalling to get the budget back on track, unplanned extra work due to faults discovered along the way and limited spare time.
When I went to install the engine back in the frame, I discovered a hairline crack in the engine cradle. Although the engine has rubber mounts reducing the amount of vibration transferred to the frame, common sense dictated that I should not ignore such an obvious weak point. A quick trip to a local aluminium welder had that problem sorted out.
During this time, I took the opportunity to superficially tidy up the expansion chambers. (exhaust pipes) I say “superficially”, as I made no attempt to reduce the carbon build up that is surely deposited on their insides. Instead, I sanded back the existing layers of paint, removed as much of the surface rust as possible, treated the remaining rust with a “rust converter” and treated the pipes to a fresh paint job with heatproof paint. Whilst being a “far from perfect” job, it should give the pipes a bit more protection against the elements.
The reinstallation of the engine, exhausts and cooling system went remarkably smoothly, given that I do not have a workshop manual. I have yet to buy myself a workshop manual for the bike. This is largely due to the fact that I used to have one and they are not cheap. I cannot quite bring myself to buying a new one. These days, “bootleg” PDF versions are available on the internet. I have found the PDF version of the RGV manual to be an incomplete series of bad quality scanned in images. Still, using this and referring back to photos I took of the bike at the beginning of the year meant I did not end up with “bits left over”.
Once it was back in one piece, half a litre of fuel and the battery were “borrowed” from the VFR, and I was able to fire the bike back into life quite easily. The “build” itself still has a fair way to go. The high-level short list comprises of: