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Measure Twice...Again!
With the new engine mated to the gearbox we lower the assembly to align the mountings. There’s something wrong. The cossy engine has a Mexico RS2000 sump and this seems to have extra casting shapes at each side at the rear. These just stop it dropping through the frame. Maybe if we hoist it higher and drop it it will force its way through?
The dropping technique fails and so we lever the frame away from the engine slightly to let it drop. This works, but it drops too far. In order to mate with the mountings it needs to be right in the centre of the frame bars themselves. Out comes the engine again so that the offending alloy can be filed away....We lower the engine again. The sump section passes through the frame now and we breathe a sigh of relief. We try to align both mountings but the engine tilts badly. A check reveals that the starter motor is now fouling the frame on the opposite side. It will have to come out and have one of its three mounting flanges cut off to enable the assembly to pass through the frame. But it is now wedged and cannot be dropped from below either. So, out with the engine yet again…
...We are checking the clutch actuator. Something seems strange as whichever way we try it we just cannot get the cable fitted so that it pulls the clutch lever in the correct direction. The cable adjuster comes and goes a score of times but no joy...It is almost as if the design requires the cable outer to push against the actuator instead of the cable pulling it. How odd. Must be wrong?
Some days later we confirm that the design requires the cable outer to push against the actuator...