Frame

Started frame assembly. Even just this first step makes it look recognisably like a bike.

From Triumph 650 rebuild

Primary

Fitted primary drive with new chain, cleaned-up clutch parts.

From Triumph 650 rebuild

Back in Black...

Frame parts back from powdercoating. The fasteners needed to screw this lot back together have been zinc-plated, so it'll all look pretty fresh when it's assembled.

From Triumph 650 rebuild

Jugs & slugs

Fitted the slugs into the jugs (pistons into the cylinders for those not down with the lingo), propped the whole lot above the conrods then slid the new gudgeon pins into place and fitted the circlips. Bolted the jugs down onto the cases

From Triumph 650 rebuild

From Triumph 650 rebuild

Also managed to get the gears installed after several attempts. No problem with the gears or shafts, just getting the indexing correct between the gearshifter and the shift camplate. Get this wrong (very easy to do!) and the transmission will shift past fourth (top) or first (bottom) and lock the gearbox. Still, it's done right now.

From Triumph 650 rebuild

Motor part III

Fitted crank & cam pinions. Installed top gear and a new sprocket.

From Triumph 650 rebuild

Motor part II

Fitted new shells to the rods and fitted them to the crank. Warmed up the drive-side inner roller bearing and slipped it onto the crank. Propped up the left-hand case and dropped the crank assembly into place. It hung up with 1/4" to go, so I ran a blowlamp over the case, allowing it and the outer main bearing race to ease just a fraction until the crank slid down the last little bit. Added some anaerobic instant gasket and bolted down the right-hand case.

Motor

Now that all the components have been cleaned and/or machined it's finally time to start slotting it all together. I'm delighted to say that I'm going to be assisted by Matthew (aged 7) performing his first engine rebuild.

From Triumph 650 rebuild