Engine Armageddon....
 

Just spoken to uncle Nelly who's managed to unearth the root of the problem with my DD engine.

Turns out the generator was loose, creating enough heat to boil the oil and melt any aluminium components within range of the magnets/windings. Apparently it's a real horror story, with that side of the engine full of molten blobs of alloy and burnt oil ("looks like armageddon in there, worst case I've ever seen"!). :o

This would explain the heat being generated in the bores as the oil wouldn't be up to the job of lubricating at the time the engine needs it most. It'd also explain the nasty, nasty noises the engine was making when I tried to start it up again.

Not sure what we're going to do but Nelly's investigating a reasonable-cost option to put it back together and see if it holds.

Ho-hum.

ali

Oh dear!

Mate, I hope you get it sorted out and back on the track quickly.

:o blimey Ali - hope his worship can fix for you mate

C

oh mate .. he did say the oil had been heated up to the extent it now smelt like gearbox oil ......

front cylinder looked ok.

That's about as bad as it's possible to be, isn't it Ali? How long is it going to take to fix? I'm sure in Nelly's capable hands it'll get sorted as soon as is superhumanly possible, though.

And failing that, if you need to raise money ...

I may know someone who might buy your Superlight if you need to sell it to keep the DD bike on the road:devil:

I'm sorry, I'll get my coat ;)

Christ, that's not the news you wanted!

Has Phil got any bits left over you could come to some arrangement over?

:lol::lol::lol:. No.

It looks like the bottom end isn't too bad, so I won't be looking for a new engine just yet. We'll just have to put it back together with new parts where necessary and see if it holds under duress. There is some wear on the back cylinder but Nelly thinks it'll hold up. Shows how good nicasil plating is, a steel bore would've welded itself to the rings a long time ago. The reality is it could've gone at anytime since I bought the bike, and I had noticed the oil getting a bit 'foamy', just didn't know enough to tell whether there was something seriously wrong or not.

So to all other DD big-bore riders, fear not, the kit is fine and you don't need to be too gentle with it, just make sure the rest of the engine's bolted together properly!

Cheers,

ali

Ali

**** fella...........is there anything of my old lump that can help..its at nellys..u r welcome to any of it m8...........

i KNOW how u feel...keep going fella..if i can help in anyway let me know....

Phil

Cheers mate, but it's exactly the same lump of metal that had been welded on yours that I'm looking for! Nelly's on the case and sounds like he can source the bits over the next few days.

Cheers,

Ali

Thats good news..at least its not a new engine dude...and has happened before the race season.....small blessings but hey you gotta take em while u can.

ready for silverstone maybe..to run her in fettle her gently.? plus its close to home LOL

Phil

[Edited on 29-3-2005 by fil2]

Sorry to hear about the probs, the good news is that she could be in no better hands than Nelly's.

Keep us updated with progress, if there's anything I can do to help, just scream.
Tim:ninja:

Blimey what rotton luck ! Hope you get it sorted ok.

Saw your bike at Cornerspeed on the way back from Cadwell on saturday Ali... The heads were off and lots of other heads were being scratched!

Hope there's a happy outcome for you mate.

n

----
Also saw TP's 996 - oh dear oh dear oh dear!
And Dibbles 996 - in for it's annual wash.

Ali, Tough call, If you want my advise whip the 900 engine of your way too fast SL and put it in the DD bike. Im sure no one will notice:lol: until you leave the grid a bit more sharpish than the rest :lol: Be rooting for a good outcome thats not too expensive. 4D

Two of the finest examples of the breed you'll find anywhere!

more than can be said about the owners. :lol::lol::lol:

Sorry to hear about your troubles Ali - spoke to the maestro today and he thought it was sortable.

Apparantly it's not quite the worst he's seen - still lags my 900 by some way! Chin up, and give us a shout if there's anything you need.

cheers, Chi

:lol: Your bike's fine, it just doesn't run! It seems Neil's got a lot more head scratching to do to get yours sorted. :( Don't worry, it'll be peachy when it comes back!

Ali mate as i said on the phone thisafternoon if you need any thing collecting and sending to Nelly's just let me know.(the offer is open to all DD competetors)
Good old Amtrak!
Butch

Ali...............fret not. It should all be back together tomorrow ;) :burn:
I've found a magnet and i've got the motor all cleaned up ready. Just need to remember where all the bits go now :sing:

Must say though, it has to be the worst alternator damage i've seen so far. The heat must have been unbelievable.
The magnets have even gone all "crunchy" :puzzled:
Anyone know the temps. required to crystalise ferrite magnets???

On a more serious note though..................i've not seen a 600 throw an alternator nut before, and now inside a fortnight there's two. Phils was a slightly "different" scenario but if you haven't done it yet, check 'em, loctite 'em and swing on 'em.
The nut on the assembly is, IMO, a worse design than the notorious SBK one and look how they like coming off.

Check ya nuts gents....................it'll hurt if it comes off ;) :P

Damn bad luck Ali....

Still trying to get my head around this - did the two parts of the generator rub together and create the heat or did something else happen?

Quite worrying really for all us 'SS/SL' dudes.

If I can can be of be of any help, just shout.

Regards - Frank

Glad to hear its not as bad as first thought, now you need to get some track time on your bike:)

dave

Many thanks for all the offers of help guys, it's what make's the club what it is. :D

Looks like Nelly's got all the bits we need for the moment, just a question of seeing how she runs when the motor's back together.

A massive shout out to Nelly for clearing the decks and getting to work on a problem that had nothing to do with the Big Bore kit. It's all to easy to forget the kind of service you'd receive at a 'normal' dealer when something like this happens. Top bloke doing a great job.:burn:

Dave: you're bang on the mark. Really nervous about not having enough setup time on track.

Don't suppose anyone's coming down from the Nottingham area this weekend with space for a bike????!

Cheers all,

Ali

Ali, do you want to split the cost of van hire and nip up there, collect mine from Grantham and yours from Nelly's? I won't be much use loading/unloading as still injured but I'm sure there'll be someone around to lend a hand. Then I can get to work on mending my panel. :D

"Dave: you're bang on the mark. Really nervous about not having enough setup time on track. "


Silverstone 17th ( sunday ) april..95 quid national circuit..has to be an option Ali.?

Phil

[Edited on 30-3-2005 by fil2]

sat april 23rd cadwell, focused events ???

Both, if the bike's up and running!

Ruthie: Sounds like a plan. Can't do this Sat. morning unless I cancel my 900's MOT (possible). Could do Sat afty or Sunday, or next weekend. Have a feeling you'll be a bit busy next weekend though.

Ali, I'll be at this as well with Tonio on his Sport.

You know you want to ...

yes better that you go to a due track if you can.............

i chose silverstone as its local to me and all i want to do is stretch the legs of the big bore kit and dont fancy a huge day in the van......
also the cads on the 23rd is way way to close to comfort if "er" shall we say something goes wrong.........time will be of the essence then and i dont want to run the risk of not making the first race due to complications lol

Phil

Ali,if its any help i could nip up to Nellys and pick the DD up on saturday and run it down to you.
Wouldnt mind meeting Nelly and it seems silly hiring a van when ive got 15 of them sitting idle at weekends.
Ring me if thats any use.
Butch

Very generous, nice one Butch.

nice 1..................

Ali, I'd nab that offer from butch if I were you. I can sort my bike out later this month.

:bouncy::bouncy:

That's a hugely generous offer Butch! I'll drop you a line this afternoon.

Cheers,

Ali

Ali,as stated i will pick it up saturday,Chris has offered to run it in for you at Rockingham sunday, he says he will post whats left to you on monday!!!!
Butch

Butch, fire me an e-mail and i'll send you some directions. It's a little tough to find first time ;)

Ali, she's all done. She runs OK. The oil was shot to pieces. I've filled with her "cheap stuff" and ran her and left her draining over night. I'll fill up with semi on Friday and she'll be all set for collection on Saturday.

Nooooooooooooooo!!!! I've seen him ride! Butcher by name etc.......:lol:

Bingo! Less than a week and youre back track, Ali. :D

Thanks Neil. Do you never stop working??
I'll drop you a line tomorrow (or Friday if you're taking a break) to sort out the details.

I know and I've done bugger all!! Fordie, Nelly and Butch have made it possible.