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the heart of darkness--splitting the cases
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Dang. I've got parts EVERYWHERE. Found clutch plates broken in several places.
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That's normal. Thermodynamic scientists call this "enthropy". ;-)
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*ugh* Was that kinda race-mod...? ;-)
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Got to the point where I needed a deep 12 mm socket to remove something
obscurely named "segment" and called it a night about 10 pm last night. The part
above the segment had 2 little springs, 2 little spring tips, and 2 chunks of
steel that fell apart as I pulled it off. It doesn't look easy to put it back
together...something that makes the shifter work.
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Ah. I remember that part when splitting my KTM 620's case (which is
easier because of the zylindrical roller bearings in the lower end that
come apart w/o force). Did I tell you about 5 reverse gears...? ;-)
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I spent a couple hours yesterday driving all over to find a rotor holder.
Finally found some obscure Race Tech tool kicked under the shelf at a cycle
gear. Bought it, (not sure what Race Tech intended it to be used for) got the
rotor off ! and then went to take off the clutch basket and hub. Guess what, the
Motion Pro clutch holding tool I've had for probably 3 years also has 8mm studs
designed to hold the rotor...glad cycle gear has a lenient return policy.
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Ah. Cool trick! I gotta try that with my parts dealers: Buy, use, clean,
return. Might also work with valve shims... ;-)
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Off to get a 12mm deep socket. To be continued.
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No worries. I will come up to Walnut Creek if you would like.
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Thanks, I'll let you know...
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Well, it's 4:05pm, and you haven't shown up yet. Either you're doing
ok, or you've slit your wrists and have put yourself out of your
misery.
I'm guessing it's the former
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No, I've got the cases in the freezer, hoping that will help. grrrr.
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I always tought that bearings goes to the freezer and cases goes to the
oven? I mean, cold bearings and hot cases?
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Ack!
Umm. Baxter, how soon can you make that drive?
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Now now, you guys need to read a little more carefully. Bearings were STILL in
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uhh, sorry. Should've said "you guys need to read a little more
carefully." I never had mentioned the problem I was having with the old
bearings. BFH and all that.
Now back to your regularly scheduled program...
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the cases. There was a method to my apparent madness. I've always wished someone
would invent a cold gun.
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Invert a can of DustOff... helped with my KZP clutch bearings:)
BTW.... spray some on your arm. It feels cool.
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Ya know, I thought of that. If I'd had some in the house I would've tried it.
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They do... a can of freon and a spray nozzle... :)
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Although, after pounding on the bearing until I was a sweaty mess (manual "DO
NOT STRIKE BEARINGS WITH HAMMER") I had this sudden panic that maybe I was
driving them out the wrong way :)
I wasn't. They just didn't want to leave the nest, is all.
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It didn't. Thanks to Tami-n-Eric, and a bigger hammer, and the right set of
bearing drivers, it's time to start putting it all back together.
Thanks you two--made my day!
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Not changing all the seals while you are there?
What sort of gasket kit are you using? If it was a "split the cases"
teardown we normally used a Moose gasket and seal kit for "popular"
motorcycles. It is a good quality, but very cost effective kit.
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Duh. A Moose kit will be on order very shortly.
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might I humbly suggest that you purchase a bag of ideal french fries or the
like and cook a handful of them after you pull the cases out of the oven,
then throw them out... this will create a smell through out the house that
will mask any motorcycle style odor that might be left in the house
prompting a flurry of questions, being that my wife knows me well she is
suspicious when i cook, cause she knows i rarely touch the oven controls....
so far the i was hungry answer covers most odd behavior & smells
explanation... tinfoil double layered under the case is a good idea, and
wiping the oven controls & handle off when you are done removes the grease
monkey trail from her kitchen
john
gas grills on low also work in a pinch
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Mike Baxter --------------- "All GasGas, All The Time"
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That'll do.
Wasn't what came to mind though :)
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A much more pastoral image than
"Tighter that MikeW's sphincter coming around Anderson Ranch
Reservoir".
Hey Mike, I was working thru the netlist for a test board yesterday
(we lost our technician) and a lot of the nets I was working with were
CJxx and CKxx. I had a lot of trouble with the K not entering from
my keyboard. Are you missing a keyboard? :-)
-Jeff Deeney- DoD#0498 NCTR UTMA BRC COHVCO AMA
'99 ATK 260LQ-Stink Wheels '94 XR650L-HellSickle
We don't stop riding because we get old, we get old because we stop riding.
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2005 GasGas EC300, 2000 GasGas EC300, 1997 GasGas JXT270
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That should be piece of cake. Good luck!
V.
__
Mail replies to/an V B A R T H E L D at G M X dot D E
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Update
Main bearings & seals, crank installed.
Cases back together.
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Oh no, another nightmare in the making. Now that I've got everything torn apart,
I realize I didn't even need to take the segment or the spring thingy off to
remove the crank. Next time...
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Replaced all seals.
Clutch side case installed.
Replated cylinder installed, along with new piston, top bearing and pin.
Reinstalled power valve. (destroyed the little seal on power valve shaft trying
to insert it, luckily I had a spare in my box o' seals).
Engine bolted back in frame.
New clutch plates.
Clutch cover installed.
Stator & rotor installed, checked & set timing. Decided to keep the Race Tech
rotor holder--works much better than the MP.
Reattached radiator hoses, clamped cdi cable.
Since I had everything apart, decided to replace the rear shock upper & lower
bearings.
For today:
Put in coolant & trans oil.
Reattach the chain & sprocket, shift lever, kick start lever.
Replace a few bent spokes in rear wheel.
Put all the body parts back on.
Cross my fingers and kick it to life...
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Added:
Replaced reeds & VForce gasket.
Install carb (took forever, because the rubber gasket that fits in the top of
the throttle slide cover wouldn't stay on. Finally put some spray adhesive on
it).
One of the bent spokes decided it didn't want to come out; nipple broke; angle
grinder took care of the spoke. Wish I had a bolt cutter like the factory teams
use to remove a spoke.
Started on third kick.
Pretty cool feeling.
Thanks to everyone who encouraged me and gave me help !!!
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Who da man? You da man!
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Aw, shucks!
The first thing I did was run it through all 5 gears...
Of course, I'd checked it while the engine was still on the bench, at least
three times, but I was thinking of you :)
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Too bad. If you could have come up with a "special" shift pattern like
Mike did, you could have let someone's 11 year old kid take it out for
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CO2 fire extinguisher is your friend.....
another way involves air venturies
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That's pretty cool! I love industrial spot processes.
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or if someones ex wife is around just have her look at them & fall off>
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a test ride without warning him about the "special" shift pattern. It
sure got the 11 Y.O. kids attention when he tried to click it up from
that ridiculously high 3 gear into 4th...
Tim H
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VBG!
Mike Baxter --------------- "All GasGas, All The Time"
2005 GasGas EC300, 2000 GasGas EC300, 1997 GasGas JXT270
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Mike Baxter --------------- "All GasGas, All The Time"
2005 GasGas EC300, 2000 GasGas EC300, 1997 GasGas JXT270
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