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Case preparation advice request. #759072 12/12/18 6:12 pm
Joined: Feb 2018
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Tracey Spear Offline OP
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The cylinders are off for bore, and the head's being refurbished. I can't do anything more to the crank till I get the pistons back from the machinist. I ordered a second round of parts, when they arrive I will be in all kinds of rebuild mode. But for now the next step and subject of this post is how to prepare the case for assembly. So.....keeping in mind that this is my first ever engine rebuild, and I don't know %&@t.

How does one properly prepare the A65 case for assembly?

So far I've soaked in mineral spirits and cleaned the surface crud with brushes and scrubbers.

I recon need to do that again with clean solvent and focus on all the oil passages. What about the sealing surface preparation, studs left undisturbed, etc?

I buggered the case getting the cylinder off. I've ordered new cylinder studs. I plan to bolt the case together and clean up that joint with sandpaper stuck to glass.

I'm a bit foggy on replacing the various oil seals. The books I have aren't very detailed.

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Re: Case preparation advice request. [Re: Tracey Spear] #759087 12/12/18 7:17 pm
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htown Offline
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What are you doing about the timing side bush and drive side main bearing?
I highly recommend getting the book "Building Budget Brits" by Mike Brown. Usually on amazon at around 20$. He also has some CD's available that are helpful.
A65 bottom end is more sensitive to being done precisely than other Brit bikes and he explains how to do it well.


1978 Bonneville T140E
1974 Trident
1970 BSA Thunderbolt
1971 Norton Commando
1972 Norton Commando
1973 Norton Commando
1974 Norton Commando
2018 Kawasaki Z900RS


Everything will be alright in the end. If its not alright, its not the end.
Re: Case preparation advice request. [Re: Tracey Spear] #759093 12/12/18 8:11 pm
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Tracey Spear Offline OP
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Prior to tear down I could not discern any movement of the crank in the timing bush. Even with a dial indicator. I'm leaving it alone. The Drive side bearing will be replaced simply because it's been setting for 40 years.
I have Brown's book and it's been very helpful. Even more helpful have been the folks on Brit Bike.

Re: Case preparation advice request. [Re: Tracey Spear] #759110 12/12/18 11:14 pm
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Triless Offline
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After all the deburring, etc, and with all ferrous metal bits removed, I give crankcase halves a through washing and scrub with nylon brushes and "scotchbrite" pads in hot, soapy water ! Then do it again ! Dry of with compressed air. Then clean in solvent !

Re: Case preparation advice request. [Re: Tracey Spear] #759111 12/12/18 11:18 pm
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htown Offline
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Sounds like good news on the timing side bush.


1978 Bonneville T140E
1974 Trident
1970 BSA Thunderbolt
1971 Norton Commando
1972 Norton Commando
1973 Norton Commando
1974 Norton Commando
2018 Kawasaki Z900RS


Everything will be alright in the end. If its not alright, its not the end.
Re: Case preparation advice request. [Re: Tracey Spear] #759134 12/13/18 2:08 am
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gavin eisler Online Content
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"I buggered the case getting the cylinder off. I've ordered new cylinder studs. I plan to bolt the case together and clean up that joint with sandpaper stuck to glass."

Make sure all the case half fasteners are in place and torqued to spec when you do this, ideally do it with the crank, in place to guarantee alignment, if there are divots in the surface consider filling them with epoxy rather than removing excess material.



71 Devimead A65 750
56 Norbsa 68 Longstroke A65
Cagiva Raptor 650
MZ TS 250
The poster formerly known as Pod
Re: Case preparation advice request. [Re: gavin eisler] #759158 12/13/18 12:26 pm
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pushrod tom Offline
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Good advice Gavin. I would suggest installing the cam also. If everything spins freely then torque her up. Mr Healy has suggested that one should check the cylinder surface to make sure it is square with the crank. Or.... for 'normal' boogers one can use a file. PRT

Re: Case preparation advice request. [Re: Tracey Spear] #759183 12/13/18 5:22 pm
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gavin eisler Online Content
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With my 71 cases, the cam wont spin free till the barrels are bolted down!


71 Devimead A65 750
56 Norbsa 68 Longstroke A65
Cagiva Raptor 650
MZ TS 250
The poster formerly known as Pod
Re: Case preparation advice request. [Re: gavin eisler] #759357 12/15/18 1:56 am
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DavidP Offline
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Originally Posted by gavin eisler
With my 71 cases, the cam wont spin free till the barrels are bolted down!

Great, so now I gotta wonder if I got my cam bushing too loose by scraping until the cam spun nicely with the cases bolted up, but without the cylinders in place?
Prussian Blue is just a waste of time. I guess you're just supposed to bolt it all together and hope it works. Just like they did at the factory. laughing


Stepping on others doesn't make you stand tall.

71 A65L "Zelda"
92 BMW K100rs "Gustav"
72 T120V cafe project "Mr. Jim"
72 T150V "Wotan"
Re: Case preparation advice request. [Re: NickL] #759373 12/15/18 4:27 am
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Triless Offline
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Well, at least there was two choices there, noisy and noisier than just much binding in the bushes !

Re: Case preparation advice request. [Re: NickL] #759378 12/15/18 5:17 am
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Triless Offline
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Too right ! A bit of a paradox, really !


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