Beta EVO MKIII build Part 2

A REAL HARD CASE!

A big box had turned up during the week. Inside the desperately needed cases from Tim at Imperial sports bike. The forward engine mount was broken pretty much where they always break along the casting line.

It took Mike about an hour and three welding rods to re-attach the broken section. These cases are not very good castings, and the section that had cracked off had a cold shut in the join. Meaning that the aluminum was not hot enough to join correctly around the flashing points in the casting process. Mean while I spent those three hours with my hands in the parts washer cleaning everything up for reassembly. With the cases finished I put them through the washer while Mike had a well earned smoke.

Repaired engine mount!

Mike set about shimming up the engine, while I continued in the parts washer. The washing did not last long before we hit a road block with the crank shims being to small, and Mike was all out of the correct size. I took a long shot and returned home to pick up the remains of my Ducati 800M, hoping that they might contain the correct shims. I stripped down the 800M and removed the crank, gearbox and shifter drum. Much to a massive fluke the crank shims were the right size. All the shims went into the shim box at Mikes for safe keeping, and I ordered another set off the net when I got home.

We made good progress with the main cases going together quickly once the shimming was right. The barrels and heads jumped on. Although the clearance of the conrods to the timing shaft raised our eyebrows. There is less than 3mm from the rods to timing shaft. After that progress slowed due to the starter motor and starter gears from the Hypermotard not fitting. As a result we had to mix and match using those from the 800M. As a result of the Sportclassic cases not having the timing trigger mounted in them, we had to use the 800M timing gear, alternator and alternator side cover as well.

Clutch side the bike flew together and by nightfall we had the thing all bolted up!

Ducati SportClassic cases repaired and loaded!