Restoration Work (Part I)

In 2005 I returned to Germany and immediately began disassembly of the bike. The magneto went off to magneto specialist BMZ and the motor pieces went to Matthias Kunz at Axel Gaenssle's machine shop. The final drive case was repaired by the simple expediency of buying a repop case from Dreher Oldtimerteile (vintage parts). This work completely used up the difference in cost between the two bikes, but I was still money ahead because so little else needed attention.

The work was done when I returned again to Germany in 2006. Sascha's friend Rolf had reassembled the bike and it seemed ready. I rode it around locally and then took it on Rolf's Richard Küchen Gedächnisfahrt (memorial rally). This should have been an ideal break-in for the newly assembled motor.

Unfortunately, the driveshaft sheared off at the front flange part way through and I had to enjoy a lovely afternoon waiting for the Lumpensammler (sag wagon; literally, the rag collector) to come by and pick me up. During the following week, Rolf helped me to get a new driveshaft turned and pressed together.

At this point I was out of time, as I planned to bring the bike home to California. Anything else that needed fixing would have to be done in the US.

Below you can see many photos of the restoration work:

Crankshaft and replaced parts
Small End Bushings
Cylinder Work
Valve Guide
A Closer Look
Rear Crank Web
Conrod Big End and Shim
Front Crank Web
The Middle Crank Web
Crankpin and Big End Bearing
Here Begins The Disassembly...
That Was Easy...
Remove the Intake Manifold and Carb
Header and Muffler
Off Comes the Cylinder
Right Piston Close Up
Left Piston
Left Cylinder from the Top Side
Left Cylinder from the Lower Side
Left Head and Gasket
Right Side Head
Right Cylinder Top
Right Cylinder Bottom
Sans Cylinders
The Lifters
Cam Lobes
Rear Axle Bearing Removal
Freestanding Motor
Quillshaft Openning
Camshaft Timing Gear
That Pesky Broken Stud
Bottom Case Half
Bird's Eye View
Crank and Top Case Half
Crank and Top Case Half again
The Breather
Flywheel and Clutch
Top Case Half and Camshaft
The Oil Pump
Oil Pump Gears
Crankshaft in a Fixture
Nice New Pistons
New Conrod Small End Bushings
Preparing the Flywheel
Flywheel Sleeve
Flywheel Sleeve Installed
New Stud
Machining Valve Guides
Valve Guide Holes
Valve Guide and Oil Seal
Cutting New Valve Seats
New Valves and Spring Collets
Refurbished Cylinder
Combustion Chamber View
Crankshaft and replaced parts
n/a