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The Mighty Nuovo Falcone VOC
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#Post#: 2306--------------------------------------------------
Banquo's Mighty Falcone top end rebuild
By: banquo Date: March 26, 2018, 6:27 pm
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It's taken a very long time, but I finally put the Mighty
Falcone back together today. I don't have any heating in the
garage, and I'm far too old for working in sub-zero conditions
these days...
Here's a summary of what was done:
The valve gear was very noisy, not so much at tickover, but at
mid engine speed it sounded like a battalion of dwarfs hammering
on steel anvils. The bike ran well enough, and didn't use any
oil.
When I took the rocker box off, I discovered a large flat on the
rocker - valve face.
HTML https://farm5.staticflickr.com/4714/40311768492_6a0ff4cf2f.jpg
HTML https://flic.kr/p/24qdmkfinrocker2
HTML https://flic.kr/p/24qdmkf
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
As we all probably know, lubrication to this face is poor, and
relies on oil spraying up from a slot in the rocker end face.
According to the Paul Friday archives, oil is supposed to be
delivered via a slot in the rocker spindle.
However, mine didn't have any slot, and instead, the bushing
inside the rocker had a groove to deliver oil to the slot.
HTML https://farm5.staticflickr.com/4767/40311767812_29c6b5b5d6_z.jpg
HTML https://flic.kr/p/24qdm8wslot
align
HTML https://flic.kr/p/24qdm8w
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm5.staticflickr.com/4398/35777910673_ba587ed83d_z.jpg
HTML https://flic.kr/p/Wvz9mRarm
slot
HTML https://flic.kr/p/Wvz9mR
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
This is probably an improvement, as you don't need to worry
about aligning the spindle slot with the slot in the rocker.
However, it clearly didn't work. I had foolishly decided that as
I do very small mileages on the Mighty Falcone, I didn't need to
bother with an oil feed. The bike has only done 21,000 km since
I got it in 2002, and it was some surprise to see so much wear
with such low use.
The standard fix is to add a second oil feed to the banjo
fitting on the right side of the head. However, I have always
thought this very ugly, and devised a new system where the
spindle is drilled from the left side, so only a short copper
pipe is required. See post:
HTML http://nuovofalcone.createaforum.com/engine-and-transmission/alternative-inlet-rocker-oil-line/
Of course I broke an exhaust stud, and there was no way it
wanted to come out, even after soaking for a week in Plus Gas...
HTML https://farm5.staticflickr.com/4716/39459893085_b6f3f140d6_z.jpg
HTML https://flic.kr/p/237Wgseplus
gas
HTML https://flic.kr/p/237Wgse
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
The valves were in good shape with hardly any wear or burnt
faces. A serious decoke was required though, and it's clearly
running quite rich...
HTML https://farm5.staticflickr.com/4708/39459893445_90e290edfb_z.jpg
HTML https://flic.kr/p/237Wgyrcombustion
chamber
HTML https://flic.kr/p/237Wgyr
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm1.staticflickr.com/821/41024941301_83054abd61_z.jpg
HTML https://flic.kr/p/25vexLacrown2
HTML https://flic.kr/p/25vexLa
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
My troubles didn't end there.
On stripping the head, I discovered significant wear in the
valve guides (and I believe that this is a precursor to stuck
valves and catastrophic failure, as we never hear of dropped
valves on new or recently rebuilt engines). I could have simply
replaced the guides, but decided to have the head professionally
rebuilt with smaller valve stems (8mm and 9mm), oil seals on the
guides, and lighter springs. The smaller stems are supposed to
be better, but dropped valves have occurred also with them, so
they're not bulletproof (according to Huub, who has experience
of that). However, the lighter springs reduce loading on the
camshaft and cam followers, so it seemed to be the way to go. I
was fortunate to have a good friend, who organised having the
head rebuilt.
This was the end result - better than new!
HTML https://farm5.staticflickr.com/4608/26486382328_a51da4dd60_z.jpg
HTML https://flic.kr/p/GmvCGhhead
top
HTML https://flic.kr/p/GmvCGh
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Ports were polished
HTML https://farm5.staticflickr.com/4740/26486382648_29fb9906af_z.jpg
HTML https://flic.kr/p/GmvCMNexhaust
port
HTML https://flic.kr/p/GmvCMN
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm5.staticflickr.com/4724/38547498900_6cef538347_z.jpg
HTML https://flic.kr/p/21Jj1s1inlet
tract
HTML https://flic.kr/p/21Jj1s1
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
The new valves are a little shorter, so caps are supplied to
extend them to the correct length:
HTML https://farm5.staticflickr.com/4666/38547498730_bec2db3007_z.jpg
HTML https://flic.kr/p/21Jj1p5stem
caps
HTML https://flic.kr/p/21Jj1p5
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
You can just about see the oil seal in this photo, and the
lighter springs:
HTML https://farm5.staticflickr.com/4702/38547500010_5f5da401d8_z.jpg
HTML https://flic.kr/p/21Jj1M9double
2
HTML https://flic.kr/p/21Jj1M9
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
The mating face was skimmed flat:
HTML https://farm5.staticflickr.com/4766/38547499810_9708d3f88a_z.jpg
HTML https://flic.kr/p/21Jj1HGface
detail
HTML https://flic.kr/p/21Jj1HG
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
New exhaust studs and flange plate:
HTML https://farm5.staticflickr.com/4623/26486381988_65ba62b985_z.jpg
HTML https://flic.kr/p/GmvCAqexhaust
stub
HTML https://flic.kr/p/GmvCAq
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
I did consider twin-plugging the head, but was advised this was
pointless unless the engine was tuned for performance, and I
have no interest in that.
HTML https://farm5.staticflickr.com/4762/26486411108_d7c2178ee2_z.jpg
HTML https://flic.kr/p/GmvMfuIMG_0858
HTML https://flic.kr/p/GmvMfu
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
With the head off, I discovered the cause of an oil leak since I
first got the bike. Whoever assembled it had fitted the pushrod
tunnel oil seal incorrectly, so it had been squashed over the
top of the head gasket, damaging both seal and head gasket:
HTML https://farm5.staticflickr.com/4761/38547461320_a979ab2e1e_z.jpg
HTML https://flic.kr/p/21JiPh5macro
HTML https://flic.kr/p/21JiPh5
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm5.staticflickr.com/4609/26486359878_a4abf93505_z.jpg
HTML https://flic.kr/p/Gmvw2dremoved
HTML https://flic.kr/p/Gmvw2d
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
I also removed the cam followers, and found pitting on the faces
that bear on the camshaft:
HTML https://farm5.staticflickr.com/4747/39646538414_b88cf007e5_z.jpg
HTML https://flic.kr/p/23pqSB9Inlet
left Ex rt
HTML https://flic.kr/p/23pqSB9
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
I bought a pair of NOS followers to replace these.
HTML https://farm5.staticflickr.com/4741/26486382278_180f7bf5ab_z.jpg
HTML https://flic.kr/p/GmvCFqlifters
HTML https://flic.kr/p/GmvCFq
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
I didn't want to pull the camshaft, but was able to inspect
through the cam follower tunnels:
Not much sign of wear on the peaks:
HTML https://farm1.staticflickr.com/792/39215910400_af1c17bdea_z.jpg
HTML https://flic.kr/p/22KnMUdcam2
HTML https://flic.kr/p/22KnMUd
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm1.staticflickr.com/812/39215909640_c7d58a8702_z.jpg
HTML https://flic.kr/p/22KnMF7cam4
HTML https://flic.kr/p/22KnMF7
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
For the bore, it was obvious that the barrel was rusted on the
base, and had probably been lying in a pool of water since 1972,
until I bought it 30 years later...
HTML https://farm5.staticflickr.com/4650/40357137461_3bd807e47b_z.jpg
HTML https://flic.kr/p/24udSWRbore
HTML https://flic.kr/p/24udSWR
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
I now think I could have rebuilt without changing anything; the
engine wasn't burning oil, and I think the rust was secure in
the pits, and forming a good seal. However, I made the decision
to give it a light hone (on advice from the Engineer) but this
made the situation worse, lifting the rust out of the holes, and
opening up the pits. A rebore was required then, but I couldn't
buy a piston until I knew how much needed to be removed to clear
the pits. I had the work done at Engine Resource in Dundee (the
owner is a member of our classic bike club, the SCMC) and we
ended up with 88.4mm. This was good, as although NOS pistons are
available in all four oversizes, not all of the rings are
available. 88.4mm is available as a pattern piston from Gandini,
and it comes complete with gudgeon pin, circlips and all rings,
reducing the number of order lines.
HTML https://farm5.staticflickr.com/4743/26486382058_0401b64c73_m.jpg
HTML https://flic.kr/p/GmvCBCdomed
HTML https://flic.kr/p/GmvCBC
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm5.staticflickr.com/4701/26486382158_2dd0608586_z.jpg
HTML https://flic.kr/p/GmvCDmpiston
HTML https://flic.kr/p/GmvCDm
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
I've often wondered if gapping rings is really important, but
this photo of the oil scraper ring shows why it is; jammed solid
in the bore, with no gap at all. I used a diamond file to
adjust. The compression rings didn't need adjustment, and
actually the top ring gap was over spec.
HTML https://farm1.staticflickr.com/785/27166247368_36d9bd14cb_z.jpg
HTML https://flic.kr/p/HoA7Tjscraper
gap
HTML https://flic.kr/p/HoA7Tj
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
I decided to fit the piston on the bench as being easier than
fitting it after the piston was fitted to the con-rod:
HTML https://farm1.staticflickr.com/811/39215911060_7a641f1083_z.jpg
HTML https://flic.kr/p/22KnN6Abarrel-piston
HTML https://flic.kr/p/22KnN6A
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm1.staticflickr.com/786/27153622938_49b103719e_z.jpg
HTML https://flic.kr/p/Hntq5Jpiston
fitted2
HTML https://flic.kr/p/Hntq5J
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Then align the piston so the larger valve cutout for the inlet
valve is at the top:
HTML https://farm1.staticflickr.com/810/40131354655_974b715170_z.jpg
HTML https://flic.kr/p/249gFzRvalve
cutouts
HTML https://flic.kr/p/249gFzR
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Then fitted the barrel to the cylinder studs, warmed the piston
with a hot air gun, fitted gudgeon pin and circlips:
HTML https://farm1.staticflickr.com/816/27153624428_c06273d6e5_z.jpg
HTML https://flic.kr/p/Hntqwqbase
gasket
HTML https://flic.kr/p/Hntqwq
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm1.staticflickr.com/788/27153622688_c45c5e0a14_z.jpg
HTML https://flic.kr/p/Hntq1qgudgeon
pin
HTML https://flic.kr/p/Hntq1q
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Circlips are conventional type; not the wire ones as fitted to
the original Mondial piston
HTML https://farm1.staticflickr.com/787/39215909000_0429c1cc85_q.jpg
HTML https://flic.kr/p/22KnMu5circlip1a
HTML https://flic.kr/p/22KnMu5
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm1.staticflickr.com/821/26154124017_e40575ab4a_z.jpg
HTML https://flic.kr/p/FR9HSH3
HTML https://flic.kr/p/FR9HSH
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
That was it for the day:
HTML https://farm1.staticflickr.com/814/27153624578_87f6bed24e_z.jpg
HTML https://flic.kr/p/Hntqz1barrel
fitted2
HTML https://flic.kr/p/Hntqz1
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
New gasket and pushrod tunnel seal:
HTML https://farm1.staticflickr.com/804/26166997217_0f16171c92_z.jpg
HTML https://flic.kr/p/FShGCrhead
gasket
HTML https://flic.kr/p/FShGCr
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Torque head to 45 N-m
HTML https://farm1.staticflickr.com/900/39229092530_9f664f0fc7_z.jpg
HTML https://flic.kr/p/22Lxmujtorque
HTML https://flic.kr/p/22Lxmuj
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Fitted pushrods (inlet is nearest the crankshaft and exhaust
nearest timing side:
HTML https://farm1.staticflickr.com/788/27166247758_6a862ff99f_q.jpg
HTML https://flic.kr/p/HoA813pushrod
alignment
HTML https://flic.kr/p/HoA813
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
HTML https://farm1.staticflickr.com/801/39229093170_041288861c_z.jpg
HTML https://flic.kr/p/22LxmFmhead
fitted
HTML https://flic.kr/p/22LxmFm
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Fitted the valve caps with grease to hold them in, then fitted
rocker box:
HTML https://farm1.staticflickr.com/793/40995775222_d874779fa0_z.jpg
HTML https://flic.kr/p/25sE4GJvalve
caps
HTML https://flic.kr/p/25sE4GJ
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Good view of oil seal on this one:
HTML https://farm1.staticflickr.com/864/40995775432_a5e2eb6ec4_z.jpg
HTML https://flic.kr/p/25sE4Lmoil
seal
HTML https://flic.kr/p/25sE4Lm
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Bit of a fiddle locating pushrods into rockers:
HTML https://farm1.staticflickr.com/864/39229092760_2373dce8fc_z.jpg
HTML https://flic.kr/p/22Lxmyhpushrod-rockers
HTML https://flic.kr/p/22Lxmyh
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
Added the new oil feed:
HTML https://farm1.staticflickr.com/794/39229093130_f13ba9e4d6_z.jpg
HTML https://flic.kr/p/22LxmEEoil
feed
HTML https://flic.kr/p/22LxmEE
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
After that, it was just fitting exhaust, carburettor, spark plug
etc. and set the valve clearances (I use 0.1 and 0.2mm)
I kicked over the bike a few times to get some fresh oil through
the system, and was pleased to see oil being delivered from the
new feed to the inlet rocker: note position of end float spring
on inlet rocker shaft to left of engine; exhaust is on the right
side:
HTML https://farm1.staticflickr.com/895/26167161197_f6bc07b0cf_z.jpg
HTML https://flic.kr/p/FSixnFoilfeed
proof
HTML https://flic.kr/p/FSixnF
by bancquo
HTML https://www.flickr.com/photos/17279292@N03/,
on Flickr
And that's pretty much it. I'm not a confident engine builder
:-[ so I won't be happy until I've done a few hundred miles on
it, but on the plus side, it did start second kick. A bit smoky
at first, as all the assembly oil burned off, but that soon
cleared. Fingers crossed that I haven't screwed up on anything,
and that we have a few thousand miles before the next time...
HTML https://youtu.be/Ao_rBjkrCwQ
#Post#: 2308--------------------------------------------------
Re: Banquo's Mighty Falcone top end rebuild
By: guest107 Date: March 28, 2018, 1:38 am
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beau travail félicitations , c'est reparti pour quelques
décennies
#Post#: 2309--------------------------------------------------
Re: Banquo's Mighty Falcone top end rebuild
By: banquo Date: March 28, 2018, 12:25 pm
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J'espère que si mono; Merci pour vos commentaires
#Post#: 2311--------------------------------------------------
Re: Banquo's Mighty Falcone top end rebuild
By: JamesNFalconaut Date: March 28, 2018, 7:51 pm
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Great photos and documentation Banquo.
Will be very useful when I do my head (in) with new valves
#Post#: 2312--------------------------------------------------
Re: Banquo's Mighty Falcone top end rebuild
By: banquo Date: March 29, 2018, 6:13 am
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Hope it goes well for you; I would have had mine assembled
earlier, but this winter has been six months of cold, snow and
more cold....
#Post#: 2313--------------------------------------------------
Re: Banquo's Mighty Falcone top end rebuild
By: olebmw Date: March 29, 2018, 2:35 pm
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Where did you get your light weight valve kit?
#Post#: 2314--------------------------------------------------
Re: Banquo's Mighty Falcone top end rebuild
By: banquo Date: March 31, 2018, 7:28 am
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I had the work done for me by Fischer in Volkach in Germany.
I believe the valve conversion is the same as the ones supplied
by Pirner
#Post#: 2409--------------------------------------------------
Re: Banquo's Mighty Falcone top end rebuild
By: Sigean Date: July 12, 2018, 11:54 am
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Hi,
Great article about the Falcone's renovation. I particularly
liked the new oil feel design - very neat!
I don't think I have input to this forum since my return from
France a couple of summers ago on my Falcone, when its engine
dropped an exhaust valve. A sad end to a 5000 mile trip through
France, Italy and Austria...... I have left the bike in the
shed whilst pondering its fate, and during the intervening time
have bought a couple of modern bikes, a Honda XR400 and a CCM
404E. The Honda has provided a significant distraction, not
least from its fantastic performance and great fuel consumption
and is with me in southern France right now, but it seems to
burn oil like a two-stroke, and after only 10k miles(!) - must
look at that after my return to the UK. The CCM is still in the
workshop, its charms yet to be revealed.
But your article has me thinking that an engine overhaul might
be the best way forward for the Falcone, and a power upgrade by
having the head welded as I have seen in some other parts of
this forum. Much food for thought, and I hope you will not mind
if I am in touch through these pages for specific points to be
cleared up as they arise.
#Post#: 2410--------------------------------------------------
Re: Banquo's Mighty Falcone top end rebuild
By: banquo Date: July 12, 2018, 3:02 pm
---------------------------------------------------------
Hi Sigean, you're more than welcome, although I have to say that
I don't know much more than I've posted already! Ken's ex Paul
Friday NF is the one with the squish head, and he's very happy
with the performance. I chose to keep things as stock as
possible, rightly or wrongly, although Ken's doesn't seem to
have suffered at all from the extra power.
#Post#: 2490--------------------------------------------------
Re: Banquo's Mighty Falcone top end rebuild
By: Dunders Date: October 19, 2018, 3:13 pm
---------------------------------------------------------
Very clear write-up: thanks Jake! I hope I won't have to do
that for a while, but at 20kKm it seems likely soon. The POs
had documented much work and maintenance, so I'm hoping it's
been cosseted. You never know. One of the POs did fit the
(ugly) oil mod, but then removed it because of smoking. I'm
intending to replace it this winter, possibly with an external
oil filter. There's a Cali to sort out first, though!
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