2-stroke performance engine - special JAWA piston repair 

Servus! What a great pleasure, seeing old school, skilled, heartblooded toolmakers workin'...!!! We speak the same language around the world! Keep on rollin' Andy The grey bearded german toolmaker

I like Jawa and I'm happy to see how you work with she. Perfect job. You should be a teacher at engineer school and share your nice knowledge.

Asi najlepší technik mechanik čo som videl skvelé nápady a riešenia

The ingenuity and craftsmanship is outstanding. Also added bonus of hedgehog and cat's at the shop.

Glad you're back

Vintage JAWA. A thing of beauty a joy forever.

This was like watching piston surgery! Precise work with beautiful reward! Much respect for DIY approach. Cheers!

Beautiful repairs are improvements.

used to be a great speed way bike engine , cheers from Australia

A home workshop with a cat, looks like heaven to me. Those Jawa's seemed pretty common back in New Zealand when I was a kid.

What a fortunate man you are. Have all the best tools to the job right 😅😅😅now

I love this kind of work! 👍💯

I had tried the PB bush for the wrist pin before, unfortunately the machinery I have access to wasn't able to bore out the wrist pin bore true like yours, so ended up abandoning it, but watching your video gave me some new ideas on how to achieve that in a round about way. Thank you for staying on it.

Those marks on castings are probably made by air pump which fell off its holder. Every Jawa 559 has it.

Really cool video with some great machining techniques. Thanks for sharing 😊

Danke für das super Video...ich als 250ccm 2Taktfahrer kann ne Menge lernen. ❤

Krásně si s tou Jawkou hraješ 🙂 Opět dobrá práce 👌

Fantastic video! Enjoy the new piston

Very nice work! Thank you for documenting the process and showing us your critters!

Well done, well done, amazing job!

Wow ❤...just wow 😎!! The amount of work and attention to details is really brilliant ❤❤

Superb, I loved that... many thanks

Love you Channel and your videos! From Italy

Awesome fix!

great job, best regards from Ukraine.

Ohh man. Well, great work, but I don't know if I would reuse said piston. It doesn't matter how well the repair is made, once broke, the structural integrity is changed forever. Thanks for sharing.

lovely job!!!!

A very good work.

And the knowledge needed ❤❤❤❤

Well done

Ich liebe Dich, ich meine Deine mechanischen Fähigkeiten! Grüße, Isarwasser.

Bravo !Bonne travaille 👍

The wear marks on the Jawa 559 casings that your talking about is cause by the drain bolt on the carb its is quite a common occurrence on multiple different branded 2 strokes with a similar design it happens due to vibration

💥💥💥💥💥💥💥💥

Don't worry about video aspect ratio, I got this video recommended, so apparently this is fine for youtube.

I hope you use it just like an asher!!

Great work! Which bronze did you use? Oillite?

You're sick! 😁 I was waiting for the whole 4 months for the new video. Why did you ditch tune exhausts? Thank you!

I love that you made that old fart running like a super star! I am in a little bit of a similar shoes without the machinery in my single garage. I saved an old CZ 250 twin for modifying purpose, but guess, well you don't have to guess you know, because short of financial issues and spare time having hard time getting off the bases. I collecting interesting parts and managed to get a 350 Jawa engine, 38 Mikuni, put an SV1000 front end into it, got a double swingarm to extend, strengthen and lift the rear of the bike up at least as much the front, but having issues to put myself into spend so much on the pipes, cylinder work, crank work, pointless ignition system, and so much more into it and then still stuck with a shitty clutch and transmission. I was gonna get a 500 Ninja or a crashed Aprilia 660 that come out cheaper with carbs. What do you think?

I love your metal bush sleeves question are those brass sleeves or copper sleeves amazing work on that piston😢😅😊😂😂😊❤

On my untouched jawa the piston pin is tightly pressed in the piston. What is the difference when its loose or tightly fit?

Krásna práca 👍nádherna motorka 👌. Tiež mam Jawu 559 a jazdim na nej každy deň . Vidím že si odborník a baví ťa to. Može vedieť odkial si? Len zo zvedavosti. Ďakujem🙏 . Ja som so 🇸🇰 Slovakia🇸🇰

Is that a modified cylinder with bolt on reed block or a later development from factory? I don't think I've ever worked on a JAWA, CZ or MZ that didn't have rumbling main bearings. We used to change mains on MZ at first service (1970's~80's, ~500 miles) Personally, I would have bored/reamed piston and fitted 'top hat' thin wall bronze bushings almost exactly like you did. (I did train as precision machinist before returning to motorcycle dealer servicing) That's very nice micron reading small bore gauge.

How did you convert the 559 engine to have a separate lever for starting and shifting?

😀Hei, i was waiting for cylinder build video, but its better than nothing😂. What balancing factor you used for crank?

Why didn't you heat the bushings into the piston? (sorry for the spelling - I'm using Google translator)

Hey, im doing a JAWA 350 638 build myself, what are your thoughts about putting on RD350 carbs from Yamaha on the engine, also maybe fiting some reed valves too? Also, when I was disasembling my engine, the piston pin was very tightly in the piston, I had to punch it out, is that normal or is that bad?

What are these yellow marks, two on the cylinder and one on the engine block?

I think that the wear is made from some tools due to the main jet position in the original carburetor.

Шикарно!! Какие у вас мысли про усиление коробки передач?

why use a centricator when you have a dro? dont you trust the dro?, or pherhaps dont have a small edgefinder?

Возможно было бы проще изготовить ремонтный палец увеличенного диаметра, и под него расхонинговать отверстия в поршне и в верхней головке шатуна. Подшипник при этом остаётся прежним.

how to find you on social networks I want to assemble the same motorcycle as yours 😊

Приятного аппетита ёжику

Great job! Planning to sell DIY Engine kit? Hello from Ukraine!

Hi bro, you should use the video format 16:9

откуда у тебя столько высоко точного и дорого го оборудования и инструмента ?

i would put the piston on the sun and the rings into the freezer.

Not a lot of material around that gudgeon pin bore.

Ring a ding ding, not ring a ding dang..

Bár csak a jawa gyár is így csinálta volna!

Nice repair. Sounds sweet, is the hissing during kicking over an automatic decompressor? Sounds like compression leaking from somewhere.

Increíble 🫢💪💪💪

Цилиндр не успевает охладить такой объём у вас всё правильно и акуратно но соотношение расчётов и как вы едите гробите технику включая коробку теперь поршня

Pure engineering p*rn! :)

Where is the oil!

i has young boy some jawa 250cc and has worst bike and engine what ewer i has all my life. newer not keep right ingnition and alltime need repair many.

I am from jawa😂

The thumbnail really made it look like you were going to weld up the old broken piston 💀

Mon message a été supprimé. Désolé! J'abandonne.

You should have just opened up the con rod end and make a custom wrist pin

1:13 "let's check for anything obviously wrong" removes cylinder head...yes but then removes barrel without first checking piston slap in cylinder? I guess you knew what you were going to find perhaps... or knew you were going to be able to measure piston/rings/bore accurately with gear. Bush mechanic me (not having much in the way of measuring gear) would always wiggle the piston head in the bore and scratch my head first, before taking off the barrel. I'm not trying to suggest your solution is wrong.... you're far more skilled than I have ever been..... but I'd be worried that if the brass bush turned a bit in the journal, the lubrication hole would block and things might get nasty in the top end. If I had a time machine, and video'd my first exploration of top end internals, and repair, of an old bsa 250 that I'd seized about 4 times trying to get home up a long hill (a longgg time ago).... I think folks would have been horrified by my use of hammer, chisel, hacksaw and file.... removing a broken ring and cleaning out the ring slot/lands sufficiently to fit a new ring in. The poor old beast ran for a fair while after that, until I upgraded to an early 60s C92 honda benly.

The wrist pin clips won’t work now