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Emergency Prertt Engine Replacement

Started by TonyDevil , Jul 04 2008 01:35 am

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#1 TonyDevil

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Posted 04 July 2008 - 01:35 am

uploading this via my mobile (coz my broadband is down and my router is fried sad.gif ), so lemme know if theres any probs with links etc


due to a few woes with parts my new engine aint ready dry.gif
so borrowed hutchs new engine (Guinness' old mk1 rebuilt wink.gif )
and fitted it on JHTs driveway good.gif

oh dear, this aint lookin so healthy





strip it down town



and install the replacement engine







add a little fuel



and tada



YSF1000 nut upgrade compared to the old standard 3VD one
according my local parts place its actually a yammie standard upgrade for the FZR6 which uses the same TDM





my custom Y piece measurements for those that asked



my old plugs, people following me used to complain about the smell of fuel so i assumed she was running rich
according to these it was lean doubtfull.gif




"Never argue with an idiot. They just bring you down to their level and beat you with experience"
My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips
current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
If a strange looking truck driver honks at you & gives you the thumbs up, its could be me  :good:

#2 Hawmaw

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Posted 04 July 2008 - 07:59 am

Well done Tony. Most folk (including myself) would have given up and cancelled the trip. ( I'm only seeing 5 photos though. )


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Then : Yamaha TDM850 4TX , Suzuki GSF1200N Bandit , Yamaha TDM850 3VD , Yamaha 600 Fazer , Suzuki GSXR750G , Honda CB1100F , BMW R75/5 , Yamaha RD250E , Yamaha XS250 , Kawasaki Z250C , Lambretta GP150 , Vespa 150 Super

#3 stu

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Posted 04 July 2008 - 10:05 am

QUOTE(TonyDevil @ Fri 4th Jul 2008, 02:20 AM) <{POST_SNAPBACK}>
my custom Y front measurements for those that asked

blink.gif



I can only see 5 pics too, what's the bit about the replacement nut?

Stu
 

#4 ChrisG

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Posted 04 July 2008 - 03:33 pm

I'm dissapointed in you Tony, you've actually rebuilt your bike several days before your ferry booking, this is most unlike you. rotflmmfao.gif

1992 Mk1, 76k miles, Hagon springs, MTC exhaust, 4½ gears Gone now :(
2009 900 abs, 42k miles, Yamaha heated grips, double bubble screen, R&G crash bungs, scottoiler, Autocom, 1500 lumen LED spotlights.

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#5 Guest_Cozzy_*

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Posted 04 July 2008 - 04:53 pm

Jaysus! That's some job!

#6 catsbum

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Posted 04 July 2008 - 07:38 pm

It went a bit pear shaped today as Tony was back at JHT's for emergency repairs, oil gushing out of the engine blink.gif

I'll be back after din dins with some pics and follow-up, unless the Engine crew beat me to it.

#7 ChrisG

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Posted 04 July 2008 - 07:49 pm

Eeek, he got it sorted now?


1992 Mk1, 76k miles, Hagon springs, MTC exhaust, 4½ gears Gone now :(
2009 900 abs, 42k miles, Yamaha heated grips, double bubble screen, R&G crash bungs, scottoiler, Autocom, 1500 lumen LED spotlights.

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#8 catsbum

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Posted 04 July 2008 - 10:40 pm

Got a call from Tony this morning asking if I was busy,, I was but his voice told me to help

Sure thing Slim Guy, what's up?

Wanna come to JHT's I have a problem... Sure

The pics sum up the day.....

Oil Pissing everywhere, from a freshly re-built engine.
Traced it to to the starter seal..... we thought blink.gif


After an hour and several phone calls trying to get O rings,, I was despatched home for the first aid kit


Picked up 1/4 pounder n cheese x 3 for lunch

then:
Rebuild
Tony = sad, oil everywhere


Start engine............GUSH!!!!!

Start again

Where is this coming from

Big strip
then, we see the problem:





Not fitted properly
F££k!
More work, more calls to dealers

new gaskets please

Working



FFS!!


After some 7 hours the leak is fixed and we are ready for the RTT

MASSIVE THANKS to JHT and his technical knowledge
A big guy with history and can shout the torque settings from 50m

Although<<<<< he has a builders arse


Well done all
Great day, looking forward to my awaited week
rolleyes.gif

Edited by CatsBum, 04 July 2008 - 10:43 pm.

#9 dapleb

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Posted 04 July 2008 - 10:46 pm

Hehehe good skills bhoyos.....now about that nut?
"Whats up", "Piston Broke", "Yeah me too...hic"

If you want to mark your location on the Carpe map: http://www.carpe-tdm...opic.php?t=5117

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#10 ChrisG

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Posted 05 July 2008 - 06:25 am

Phew

jht saves the day again


1992 Mk1, 76k miles, Hagon springs, MTC exhaust, 4½ gears Gone now :(
2009 900 abs, 42k miles, Yamaha heated grips, double bubble screen, R&G crash bungs, scottoiler, Autocom, 1500 lumen LED spotlights.

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#11 JollyGiant

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Posted 05 July 2008 - 07:03 am

QUOTE(CatsBum @ Fri 4th Jul 2008, 11:25 PM) <{POST_SNAPBACK}>
After an hour and several phone calls trying to get O rings,, I was despatched home for the first aid kit


Picked up 1/4 pounder n cheese x 3 for lunch


My Kinda 1st Aid kit good.gif Every mans garage should have one of those and the same kinda thang but with nuts, bolts and washers good.gif

My kinda lunch too yeahyeahyeah.gif But only with a strawberry milk shake tooo drinks.gif

My Super Modded TDM has gone to a new home :(

 

I'm now a carbon whore!

#12 catsbum

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Posted 05 July 2008 - 07:41 am

Milk shake on a Tenere? Please, imagine the mess. Nope we were healthy and had orange juice.

Update on Tony this morning though. Just txted him (he has no internet access) and asked him bout engine................... unsure.gif

"it's F$$ked mate, just heading back to the person who re-built it" punishment.gif

This is not good. Those boys spent 2 whole days on this.

I have an autocom issue, anyone who knows about these things please pm me.
Chris!!!


#13 dapleb

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Posted 05 July 2008 - 07:48 am

QUOTE(CatsBum @ Sat 5th Jul 2008, 08:26 AM) <{POST_SNAPBACK}>
"it's F$$ked mate, just heading back to the person who re-built it" :


Joke or no? unsure.gif

Tell him to send us a txt if oi can help with parts or whatever.
"Whats up", "Piston Broke", "Yeah me too...hic"

If you want to mark your location on the Carpe map: http://www.carpe-tdm...opic.php?t=5117

Doin valve clearances? Use dappers valve shim exchange program and the job will be carroty - Free (other than you postin me yer shims) for sporting members.

Active member of TPLQHCSRSFC and TSRMCMAS (even though a year off) and avid fan of PM not sent.

#14 catsbum

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Posted 05 July 2008 - 07:49 am

No joking daps mellow.gif


Will do, he has hutch with him and heading for Jenna's place. This is going to be a close call.


daps: he has a txt.

Edited by CatsBum, 05 July 2008 - 07:54 am.

#15 Guest_Catteeclan_*

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Posted 05 July 2008 - 08:34 am

ohmy.gif What a fck up. And the story continues?


Why are you using instant gasket on O rings.



#16 jht

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Posted 05 July 2008 - 08:52 am

QUOTE(Catteeclan @ Sat 5th Jul 2008, 09:19 AM) <{POST_SNAPBACK}>
ohmy.gif What a fck up. And the story continues?
Why are you using instant gasket on O rings.


We weren't.... I'd use new o rings fer a rebuild

but Jenna at Raid Xtreme who rebuilt the motor for Tony did

they appear to have applied a liberal coat of blue instant gasket to every gasket bar the base and head???

Tony gave then a new gasket set too.....

Dunno but I aint too impressed with their work that I have seen so far.....

It quickly became obvious that there something seriously wrong with their rebuilt motor so Tony got the bike recovered back to them

I aint saying nowt more, Tony can fill in the blanks

Edited by jht, 05 July 2008 - 08:54 am.

Done: Homo sap navigation/ twisty thing on bars to make it go vroom/ grabby thing to make it stop (in front of twisty thing)/ 'leccy things front and rear to make it glow at night/ Sucky + drippy oiler thing to keep chains moist (!!) / Laser Pro Stock Race pipes / bleeding ear drums (see previous mod)
To do: Educate homo sap nav system to operate twisty + grabby things/ get ear plugs

All Trashed Now... Pants... its a Cat B Mwahahaha it lives again!!


Remember every driver is a deaf myoptic twat who is out to kill you, ALWAYS assume they are going to do THE most f*cking DUMBASS, STUPID manouver possible, at the worst possible moment; get past, and get past quick

#17 Guest_Catteeclan_*

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Posted 05 July 2008 - 09:05 am

I got an old xl engine off a friend which was "rebult". Instant gasket everywhere including stuck to the oil pick up which could be why the cam and big end buggered up.

I do use the stuff but keep it to a min and never on O rings.

Hope he get an engine sorted anyway.

Edited by Catteeclan, 05 July 2008 - 09:05 am.

#18 Guest_GuyGraham_*

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Posted 05 July 2008 - 09:20 am

Never use instant gasket in a 4 stroke engine rebuild

the bloody stuff gets everywhere, and gets squeezed out of the joints when the parts are assembled
It then proceeds to get flushed round the engine blocking up oil passages and jets

Result:- 1 fecked up engine

You have been warned!

#19 lemonentrails

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Posted 05 July 2008 - 10:09 am

QUOTE(GuyGraham @ Sat 5th Jul 2008, 10:05 AM) <{POST_SNAPBACK}>
Never use instant gasket in a 4 stroke engine rebuild

the bloody stuff gets everywhere, and gets squeezed out of the joints when the parts are assembled
It then proceeds to get flushed round the engine blocking up oil passages and jets

Result:- 1 fecked up engine

You have been warned!


Never built a brit bike without it! tongue.gif

Being well aware of its magical properties to feck engines up by blocking oilways etc I've used it with care for years with no problems.The problem as i see it is that folk use the "applicator" supplied which is fine if your filling the gap around your sink! but no use for the micron thick space between properly fitting casings . Having said that i only use it as a repair when the correct gasket is not forthcoming or the sealing faces are fooked.

Mk1black ()60+k,micron system, nice but not naughty,k&n,dynojet stage 1. port job, polished head and pistons . lowered h/bars.lowered yokes 7mm ish ,Avon Storms ,top bannanas!EBC DISCs and damned fine they are too!!!..rust an all...oh and a cracked frame.Now welded up and so far so good .....Mk1 with squire sidecar sidecar,metmachex deep brace swing arm, suzuki 6" rim &car tyre , whole plot lowered a bit.sidecar heater to keep madam cosy! LL forks coming to a bike near me soon.

#20 dapleb

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Posted 05 July 2008 - 10:28 am

Think Tony is having a tad more luck now...maybe.....they had rebuilt overnight and he were just abooot to test roide.
"Whats up", "Piston Broke", "Yeah me too...hic"

If you want to mark your location on the Carpe map: http://www.carpe-tdm...opic.php?t=5117

Doin valve clearances? Use dappers valve shim exchange program and the job will be carroty - Free (other than you postin me yer shims) for sporting members.

Active member of TPLQHCSRSFC and TSRMCMAS (even though a year off) and avid fan of PM not sent.
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