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Discussion Starter · #41 ·
The forum only lets me put 10 pictures in a post so this is part 2 of today鈥檚 progress.
I managed to find the black plate which I resprayed a couple of months ago and put it somewhere safe to dry then could not find it 馃槫. I also took the baffles out a good pair of secondhand exhausts that I bought a few years ago. You remove the end cap then insert a piece of wood from the other end and the can be pushed out.
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Discussion Starter · #44 ·
Have taken the baffles out of the silencers to clean them
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Luckily they are removable which makes cleaning easier !
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The right hand baffle is very clogged!
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loads of carbon removed and I used a 9.5 mm drill to ream out the baffles tubes. This should make the bike run much better when they are refitted!
Carburettors next !
 

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Discussion Starter · #45 ·
Started to sort the carburettor鈥檚 out!
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Setting the float height and I have cleaned the float bowls and jets before reassemble.
Have made new throttle cables as the old cables were kinked and stiiff
BEFORE
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AFTER
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I then decided to polish the ridges out of the aluminium inlet manifolds
BEFORE
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AFTER
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I used a mini grinder and polisher to remove the ridges from casting. This should give the fuel a smoother less turbulent journey to the cylinder . My next task is to fit and balance the carburettor鈥檚 and refit them to the cyclinders.
 

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Discussion Starter · #47 ·
Have been fitting the new power dynamo stator and flywheel on
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Using dial gauge to get top dead centre (!tdc)
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fitting the new stator and aligning the mark with the fin
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flywheel loosely fitted and aligned with timing mark . Digital degree meter fitted to flywheel and Zeroed!
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The flywheel is pulled forward and rotated anti clockwise until 18 degrees is showing being careful not to rotate the crankshaft ..
It can now be secured to the crankshaft
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This is the digital protractor I used it鈥檚 magnetic and I used a jubilee clip on the puller to secure it.
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finalising some of the connections and getting close to starting the engine!
 
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Discussion Starter · #48 ·
A problem which has been highlighted by my friend Selwyn at Selwyn Motorcyles is that the power dynamo flywheel touches the outer casing. This is solved by fitting a spacer or gasket..
I ordered some 1.6mm mm gasket paper and set about making a gasket. Luckily my dad showed me a way to make gaskets he used when he served in the British army in India and Burma. He was a Royal Electrical Mechanical Engineer and he taught me and my brother loads of things which have served me well in keeping my Benelli鈥檚 on the road.
Firstly you smear the casing with grease and then press it against the paper to make a pattern to cut out.
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These punches are used to make holes in the gasket they are from my dads old work shop.
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Having sorted out the casing I put some oil in the gearbox and kicked the bike over to check for a spark. All was good it has a nice strong spark ! And I am nearing to start the engine.
 
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Discussion Starter · #49 ·
I started the bike on the 2nd kick! Result, I have some wiring things to finish and I had a fuel tap leak. But the engine ticks over and revs ok hopefully I will road test it soon!
 

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Discussion Starter · #50 ·
I replaced 2 fuel taps and fitted some new fibre washers on the carbs and all the leaks are sorted. Finalised the wiring so the kill switch and ignition cut out the new powerdynamo ignition. I need to give the bike a check all over the nuts and bolts then I can test ride it and get it in the road !
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Discussion Starter · #51 ·
Went out for a shake down run, everything worked as it should. I have got to adjust the rear brake pedal and mirrors ! I had a small clutch slip but this went after a few miles. I think the plates must have glassed over whilst it鈥檚 not been run for 2 years. It has taken me twice as long as I thought it would having covid hasn鈥檛 helped. I am going on a small bike run around the Chilterns on Sunday perfect for running in. Will post pictures of the finished bike
 

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Discussion Starter · #52 ·
Here are some pictures of the final result
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Went on great run around the Chilterns today clocked up 100 trouble free miles. The engine has loosened up a lot since the new barrels and pistons were fitted. The clutch ideas slip so that will need looking at!
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Took some photos at RAF Walters Ash and photographed the Benelli under the Hurricane.
All in All a fab day out !
 

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Here are some pictures of the final result
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Went on great run around the Chilterns today clocked up 100 trouble free miles. The engine has loosened up a lot since the new barrels and pistons were fitted. The clutch ideas slip so that will need looking at!
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Took some photos at RAF Walters Ash and photographed the Benelli under the Hurricane.
All in All a fab day out !
Beautiful Benelli !
 
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