Project 1995 ABY. Getting an S2 onto irish roads.

[Ruffiano]

Gotta love the crank bolt... this is one of my favorite timing belt change pictures...

[irishs2]

lol classic.

I also got these ..


But thats for my winter rebuild. Getting it nct'd and on the road is priority now.

[S2central.net]

Double check the timing marks - I wouldn't trust the mark on the cambelt cover down at the crank pulley so much - its the flywheel is more accurate... But the only issue with that is that the timing line is hard to see - I documented this in my 'how to' - need to be clever where you apply a dab of paint to see when it lines up sweet.

[S2central.net]

Gotta love the crank bolt... this is one of my favorite timing belt change pictures...

Brilliant - man that would be some torque ... Great photo - only a true auto anorak would appreciate it.

[irishs2]

Thanks paul, and for your pdf document, yea its by the flywheel I am judging where the line just passes the lip of the casing. had to mark it like >[ so on the flywheel, so I see the edge of the line. I wasnt judging by a bolt on cover

[S2central.net]

Grand then - jus checking - you are making good progress !

[mcandmar]

Ok, Got my 1995 S2 just less than two weeks ago. Knowing full well from my lurking here that I will be digging deep in more ways than one. This is a great forum , I may not say much, but most of my questions are answered by the search function

/offtopic, Do you have a brother called Alan whos into bikes

[irishs2]

lol yes

[mcandmar]

LOL this country is way too small, Two of my mates who run cbr250.com know him from the forum, they were telling me last night his brother in Cork just bought an S2, figured it had to be you

[S2central.net]

Not so stealthy after all then the old S2 - recognition - brilliant

[irishs2]

Yea its weird, but in a good way I think. I heard one of those cbr250.com guys is a machine at go carting

Anyway..



Back together and running smoothly, at least it is now. I had a bit of a whine, thinking it was my steering pump or alternator first, I slackened those a bit, nope still whining and yep, must be the water pump or tensioner pully. I rechecked the cam belt, and reinterpreted the 'turn 90 between forefinger and thumb tightness methodoligy'

Smooth as silk. a slight bit worried about the cooling system, head +intake man. seems to get very warm but water is staying cool, but I only ran it for a few minutes.
Will check it further tomorrow.

[S2central.net]

Have you bled out the air in coolant system yet ?

[irishs2]

well I undid the top nut on top of the main rad and filled the system, while squeesing hozes to flush water through the system trying to get out air, I dont know what to do next only keep an eye on it.

[Big Lee M]

To bleed it up right you need to check the release screw on the pipe that leads to the heater matrix. Be VERY carefull with it as the break easy...........................I know! You are making brilliant progress,keep up the good work.

Good luck with the rest of it.

[irishs2]

Long time no update but work hasnt stopped on the S2, here is a quick run down on what has been done



The main exhaust mount had collapsed, causing extra strain on the join over the rear axle. End result was the back box pipe was resting on the inner cv joint wearing on it, and causing rattling.



I had to use a bolt cutters to get those rusted exhaust bolts out.



Repaired mount, eventually going for an ss system, so in the meantime a repair will do.





A new diff mount, the old one was completely destroyed.

Between work, raising funds on the bay for s2 trinkets and summer heat I took a break from the s2, just doing the small things like wipers, pipes small things that needed attention. During this time the Bosch silver battery died and would not take a charge even with a battery charger. Alternator seemed fine. In a sweet deal I got a Banner 74Ah battery with 2 year in exchange for a laptop virus repair.

After sourcing the avus wheels on the bay who turned out to be a forum member, and waiting weeks for them thing began to come together.

Until yesterday. The gear change ball joint thingy failed and I kept getting reverse too easily, 2nd gear was a real problem.




The rubber has broken down allowing bypast of the reverse lockout.


Although I had the correct part on order, I still needed to have a solution as the test was today and there would be a financial penalty if I cancelled the test.

The solution was to screw two stainless screws about 1.5" long into the sides of the unit, taking the place of the broken down rubber. It worked a treat and gear selection is now smooth and positive, well at least for a while



The car sailed through the NCT. A bit suprised as I though emissions or the knock from the left front would fail it. Emissions were tight on 2870rpm with 0.30% where a value greater than 0.30% would fail.



My daily S2 as we dont have multicar policies here, this is going to be my daily until April, when I can shop around for insurance again. Try and get a mirrored policy for the A6.

Not done yet though, probably never quite done. I still have H+R and konis to fit from vagrallye when they arrive, need to give it the powerflex treatment and while I am at it fit new track ends and balljoints. Got to get new subframe mounts for sure as there is certainly play there. Then full alignment.

Onwards..