Just taken it apart to see what damage is done, and the bottom barrel and piston are fine - thought they might be, stuck out in the breeze.

The I took the top off. Hmmm, doesn't look too bad... Barrel nuts off, and lift... No. Heave... No. Whack with a hammer... No. Oh dear, this feels bad.

Get bigger hammer and put screwdriver in barrel handle first, then whack end of screwdriver until you sweat... ooh, a minute movement! Continue until the barrel will twist, and then graunch it off.

Oh dear, looks uuuugly. Batter the pistonpin out, and remove the piston. Crank looks okay, let's give it a whirl... Oh. It's stopped. Er, what's that bit doing in there? Ah, it's a broken off piece of piston skirt.

Ah well, that'll be a crankcase split needed then. Guess it's not gonna be ready for the weekend!

What a perfect excuse to get the dremel out and clean up the cast marks and transfer ports. There's always a bright side eh?
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MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball

Sorry to hear about that Dave, anything we can do to help get it going again for the weekend?
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If I have to take the carbs off once more...

Dave, hat's off to you and anyone who can see the bright side in that! Maybe I missed it but what do you suppose led to this "opportunity" to split the cases? Good luck with the rebuild.
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-Jim
'93 MC21

The pipe to the right cylinder / radiator came out from the barrel, and of course it dumped the coolant without me realizing. I felt the engine loosing a little power, but thought it was plugs fouling since I know it's running rich.

It got so hot on the upper cylinder, that the rubber coolant hose has melted where it fits over the pipe!

What I want - NEED - to know, is why that pipe came out? I pushed it back in again easily, but now the motor is cool I can't shift it. I did half a track day at Llandow and it was fine, and I'd already done 60 miles when it happened, so I'm a bit lost and rather concerned.

I did have that barrel replated recently, so the pipe has been out, but as far as I know they're just a press fit and tighten up when the engine warms.

Does anyone actually glue these things in?

And Stephen, thanks for the offer, but I'm not sure how else to get the bits out of the crankcase. Maybe I can just drop the engine and flush it out with petrol?

I'm gonna need a piston, rings, gudgeon pin and circlips, replate, and gaskets at the very least. I'm hoping nothing else has been damaged by the portion of piston skirt.

Another £200, but having just taxed and Insured it, itd be a shame to stick it in the shed now!
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MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball

Dave, when ever I get a cylinder replated i always use a compound (something like 424 or 246) If they are just snugg I turn up a new pipe and press it it at work.

Parts required, i may have a barrel that will go again with out plating. I will have to have another look at it. I have base gaskets etc in stock at my house but I dont have a 21 piston or head gasket.
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If I have to take the carbs off once more...

Ooh, sounds promising. I can get a piston within a couple of days from Honda (at least I did last time!)

I'm just concerned at the crap in the bottom of the cases. If I don't get it all out I'm gonna wreck the crank aren't I?
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MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball

You can lift the top crank case half off the engine and remove the crank with the motor in the frame if you want. It will only cost you a clutch cover gasket. You could make sure you got everything out then.
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If I have to take the carbs off once more...

Won't even be that bad will it - it's a dry clutch.

Does the top really come off in the frame? I guess I'll have to remove EVERYTHING from the block though...
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MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball

You still have to remove the r/h engine cover (clutch cover on a wet clutch model) and clutch because it bolts onto the top crank case half.

Yes it really comes off, but you of course also have to remove the lower cylinder. Theres not much that stop of the hald comming off.
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If I have to take the carbs off once more...

Oh right. I'll give that a go tomorrow then. Cheers mate!
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MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball

No worries, sorry about that last post... went all over the shop towards the end. Im tired for some reason.
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If I have to take the carbs off once more...

I did a very similar job to Monkey's "R" just before we went away Dave, it's dead easy. Grab yourself a set of outer crank seals while you're at it if you can!

If Stephen spoke to Bill Limb nicely, they could probably muster up a 300 kit for you for the weekend... Saturday wasn't all about beers and bars - just 99% of it - we actually have confidence that "Mr. Teve's" 300 will be a relaible flier next time round!!
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Andy.
NSR-WORLD.COM

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Going back to the water pipe popping out the barrel.

Way back when grandma was a boy I stuck the things back in with araldite. Worked for me then.

Now I have somne good Alteco adhesive that's not affected by heat or gas and that works.

It's great the you have it. Can I get some over here?

Is it really sensible to rush through this in a couple of days, or am I best getting the dremel out and cleaning it all up while it's apart?

I'd love to have a go at the 300 kit, but finances won't yet allow. Since the bottom barrel is fine, I'll just get what I have to for now - I don't wanna miss what's left of the summer either!
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MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball

I've got the barrel in the vice to strip it ready for replating, and notice the PV seal is melted.

Guess that water cooling is there for a reason.
_________________
MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball