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ES2 not starting.

Submitted by andrew_pearce on Sat, 26/08/2017
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My 1960 es2 engine will not start, I'm a novice to single cylinder bikes.

I found the exhaust valve had stuck open, this was after replacing the battery, spark plug, checking the coil leads etc.

I have taking off the head disassembled the valves, removed all the carbon from the head and ensured the valves are re seated, before reassembling the engine with new gaskets etc.

I am now looking to check the engine timing and the valve clearances but am not sure how to do this.

Is there a step by step process on the forum or someone be kind enough to give some guidance please.

Any Help would be appreciated.

Submitted by adam_davis on Sun, 27/08/2017

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You say the valve lifter was stuck open at some point. Is there now compression? You should be able to stand on the kickstart for a second or two before it rolls over TDC. If not, there could be a bent valve which will need replacing.

As far as setting up the ignition timing, valve timing and clearances etc, it sounds like a workshop manual would be the best option, available from the 'Spares" department on this forum. as it's too involved for a single reply here.

Submitted by andrew_pearce on Sun, 27/08/2017

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Exhaust valve was heavily coated in carbon, they are straight. There is not compression have only tried to kick over once before writing here, the valves are now free and operating as they should.

I have a compression test gauge and will put that on today to find out what pressure the engine has.

I have the workshop manuals also.

Compression tested and is 30PSI.

Submitted by ian_soady on Sun, 27/08/2017

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I don't think you can really test compression on these bikes with a compression tester as these need it to be spun over at some speed. Follow Adam's advice - with the throttle wide open, stand on the kickstart when it's on the compression stroke. It should hold you for a few seconds. If not, you're definitely losing compression somewhere.

Did you check valve seating with the head off and valves assembled - turn it upside down and fill the combustion chamber with paraffin. There should be no (or very little) leakage past the valves over a period of several minutes. I take it you've set the tappet clearance.

Has the engine ever run as far as you know? If so, it's unlikely valve timing is off. If it hasn't a rough check is to see if the valves are just "rocking" on TDC at the end of the exhaust stroke.

Ignition timing will be dealt with in the workshop manual.

Submitted by andrew_pearce on Sun, 27/08/2017

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Previously ian_soady wrote:

I don't think you can really test compression on these bikes with a compression tester as these need it to be spun over at some speed. Follow Adam's advice - with the throttle wide open, stand on the kickstart when it's on the compression stroke. It should hold you for a few seconds. If not, you're definitely losing compression somewhere.

Did you check valve seating with the head off and valves assembled - turn it upside down and fill the combustion chamber with paraffin. There should be no (or very little) leakage past the valves over a period of several minutes. I take it you've set the tappet clearance.

Has the engine ever run as far as you know? If so, it's unlikely valve timing is off. If it hasn't a rough check is to see if the valves are just "rocking" on TDC at the end of the exhaust stroke.

Ignition timing will be dealt with in the workshop manual.

Hi Ian, there is no compression on the kick stand at all.

The valves have been reseated but will remove and check they are sealed properly with paraffin. I have not set the tappet clearance as yet.

Yes the engine was running I have run it for about 50 miles recently, then when I tried to kick it over there was no compression and the exhaust valve was stuck open.

Submitted by paul_knapp on Sun, 27/08/2017

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Before you do any more fiddling, check that the push rodsare not too tight and are not holding the valve/s open and are free to justrotate with finger with the piston at top dead centre on firing stroke, (both valves closed),as your workshop manual tells you.

Submitted by andrew_pearce on Sun, 27/08/2017

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Previously Paul Knapp wrote:

Before you do any more fiddling, check that the push rodsare not too tight and are not holding the valve/s open and are free to justrotate with finger with the piston at top dead centre on firing stroke, (both valves closed),as your workshop manual tells you.

Valves seem set correctly they are both free at what I assume is TDC no vertical movement but rotate freely, both valves closed.

Tried to turn over but just a back fire pop.

Submitted by paul_knapp on Sun, 27/08/2017

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Have you checked the de-compression lever in rocker box, front left side. It may be holding exhaust valve open a little if not adjusted correctly.

Submitted by andrew_pearce on Sun, 27/08/2017

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Previously Paul Knapp wrote:

Have you checked the de-compression lever in rocker box, front left side. It may be holding exhaust valve open a little if not adjusted correctly.

Ah......well...to my embarrassment it was the decompression valve, as soon as I've backed this off it got compression and turned first kick.

now just to set it up properly.

much appreciated Paul.

 


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