Ok, got the Permaseal / Piston & Rings / Seals & plenty of beer... here we go..!!

A good clean up first:

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Engine No: 320 200017 does the “320” make this a Lightweight or a Compact engine?
I read on Blumbley’s post when he did his re-build: https://www.outdoorking-forum.com.au/forum/u...twins-compact-restoration.html#Post61823
From his observations the Lightweight had the 409 prefix and the Compacts had 207 or 208. Apparently the Compacts had electronic ignition and the Lightweight had points? Well this one has points so maybe this one is an early or late Lightweight?


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Ah, a broken gasket... could this be part of the problem? When I last used it all of a sudden started to belch out a lot of smoke and then it wouldn’t start again until it had cooled down?


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Lower crank case off, piston out next then I can inspect the barrel for damage (this is the bit I was dreading)


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I have no experience but I don’t think this looks bad, certainly much better than I was expecting, maybe a clean up and a light hone along with the new piston/rings?


Bugger... hang on a minute, my replacement piston has a flat top..!!

I seem to remember that the rear cylinder on a 500 twin had a flat top - this must be it... what should I do now.. prise the rings/expanders off the flat one?

Last edited by Alan; 10/01/20 07:32 AM.