'64 BSA Lightning Rocket - Engine Rebuild PT I - Disassembly & Inspection

The Lightning Rocket started but ran roughly when I brought it home several years ago. The monoblocs were in poor shape and the wiring was very dodgy. With no odometer I was not sure of the miles but the title listed 12k on it. 

Engine cases coming apart which was not a problem on this one. 

I was optimistic that the engine would be in pretty good shape once it was torn down even though it looked a bit rough on the outside. The primary appears to be in decent shape but once inside the head and main cases it looks like a thorough rebuild will be needed.

The drive side main bearing felt good but most of the bushings are worn. The rod journals, large and small, looked fine although one rod bearing was a bit galled. The transmission appeared as new but one main shaft bearing felt a bit rough and will be replaced. I might as well do the needle bearings while I am in there too. The cylinders measured just a bit out of spec and will be bored one size up from stock.

A bit of scoring on the timing side bearing and piston. 

The engine cases & head were in good shape but needed a thorough cleaning. After hand scrubbing with petrol and then simple green to remove thicker chunks of goo, engine cleaner and the power washer were used to get to bare metal. Walnut blasting was applied to remove stubborn items and get the metal back to its original surface. Purple power aluminum brightener was used to get the remaining tarnish off all parts and provided very good results.

Cases cleaned, inspected and ready for new bearings. 

The cylinder was cleaned, blasted and painted with VHT gloss black engine enamel. 

It's ready for new bores.....

I had the crank ground and cam bushings replaced on my last BSA build and it looks like it will be necessary on this one as well. I have not had the cylinder or head decked in the past and have had head gasket sealing issues. I will check into decking the head and cylinder on this build and maybe the cases?  Not sure if this is needed but will check it out. This is all part of the learning process and building better bikes every time.

The head rocking a bit on the cylinder.....time to resurface one or the other...or both.

Which bearing to use on the Timing side? I am told the stock bushing lasts well when taken care of although both of the BSA's I have taken apart needed its replacement. A roller bearing conversion sounds like a good solution although I'm not sure this BSA will need it as it will have a relatively easy life once it is back on the road. More research to do.....

The main bushing journal measures .002 under, the bush measures .0015 over for a total clearance of .0035. The correct measurement should be .001. If there is to much clearance the oil pressure will drop causing increased engine wear. Looks like it's time for an intervention.

The factory punch stakes drilled out and ready to remove the plugs.

Both plugs removed with my home forged removal tool. 

All of the parts will go to my local British motorcycle machine shop in Edmore, Michigan. I will deliver all of the critical bits for them to inspect, re-machine, install new bushings and bearings as necessary. This will provide a great start for my engine build.

Heading out for machining. 

Michigan fall & the best riding of the year in this part of the country. 

It's time to get the RE out for more tuning and tweaking. Oil leaks fixed....transmission shifting good....but what to do with the oil coming out of the breather????