I build my own gaskets out of gasket paper and started putting things together.
I have a question regarding clutch and clutch cover.
- is it normal that puller in the middle of the clutch basket has some horizontal free play
- how to properly install cover because I installed it but i dont have any resistance on the clutch lever so I dont know if I did it right
3vd Engine Rebuild
Started by
danbara
, May 13 2010 08:59 am
71 replies to this topic
#61
danbara
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Posted 08 July 2010 - 07:37 am
#62
Studley Ramrod
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Posted 08 July 2010 - 09:55 am
I think there is some horizontal play on the puller.
It's a bit tricky trying to describe how to fit the clutch cover. You can download the 1996 service manual from the JBX site. You'll need to register to download the file, but it's free
http://jbx9.free.fr/tdm/index.php
Or if you wanna PM me your email addy I can send you a copy of it.
It's a bit tricky trying to describe how to fit the clutch cover. You can download the 1996 service manual from the JBX site. You'll need to register to download the file, but it's free
http://jbx9.free.fr/tdm/index.php
Or if you wanna PM me your email addy I can send you a copy of it.
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#63
danbara
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Posted 08 July 2010 - 10:54 am
I have manual from jbx site which is quite useful, but as u said it is quite tricky to put that thingy correctly.
manual said this
- install clutch plates
- install clutch cover plate
- install gasket and dowel pins
- install cover
take care that the clutch puller is facing back of the engine
and after that to install clutch lever arm on the cover body
I'll have to take it apart again and try to install it
just hope that i wont be damaging new gasket
keep your fingers crossed for me
manual said this
- install clutch plates
- install clutch cover plate
- install gasket and dowel pins
- install cover
take care that the clutch puller is facing back of the engine
and after that to install clutch lever arm on the cover body
I'll have to take it apart again and try to install it
just hope that i wont be damaging new gasket
keep your fingers crossed for me
#64
Studley Ramrod
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Posted 08 July 2010 - 01:43 pm
IIRC you have to position the lever arm so that it locates and turns as you offer the casing up to the engine. Took me 2 or 3 attempts to get it right
Fingers crossed
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#65
danbara
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Posted 09 July 2010 - 06:52 am
managed to set it properly and now it is in place.
I also didn't put clutch holding plate correctly so I did that as well since it is already opened.
than went to the other side of the engine and installed starter engine, magnet and small sprocket that is transferring power from starter to the engine
and than came the tricky part - to bolt the magnet back. I used my old holder which i used when i was unbolting it but this time it broke so now I have to bill something because it is waist of money to by tool which will be used only once.
i'm thinking of using wooden plank and old belt - attach the belt to the plank and make something like brian did
hope it will work because it needs 130 nm of torque
I also didn't put clutch holding plate correctly so I did that as well since it is already opened.
than went to the other side of the engine and installed starter engine, magnet and small sprocket that is transferring power from starter to the engine
and than came the tricky part - to bolt the magnet back. I used my old holder which i used when i was unbolting it but this time it broke so now I have to bill something because it is waist of money to by tool which will be used only once.
i'm thinking of using wooden plank and old belt - attach the belt to the plank and make something like brian did
hope it will work because it needs 130 nm of torque
#66
dapleb
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Posted 09 July 2010 - 07:36 am
Yeah that should work. You are getting there. 
"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.
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.
#67
danbara
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Posted 09 August 2010 - 08:35 pm
It's alive!!!!!!
it's alive!!!!!!
finally put the engine together, bolt it onto the frame and connected those 1000 pipes and leads,
put the battery on and started it.
firstly she hesitated, ( probably dried carbs ) and than started only with one cylinder
I thought , what a h..... and than all-the-sudden revs started to rise up to 2000 -3000 rpms
put the choke out and the engine idled around 1000 rpms
will post pics latter
it's alive!!!!!!
finally put the engine together, bolt it onto the frame and connected those 1000 pipes and leads,
put the battery on and started it.
firstly she hesitated, ( probably dried carbs ) and than started only with one cylinder
I thought , what a h..... and than all-the-sudden revs started to rise up to 2000 -3000 rpms
put the choke out and the engine idled around 1000 rpms
will post pics latter
Edited by danbara, 09 August 2010 - 08:36 pm.
#68
dapleb
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Posted 09 August 2010 - 08:50 pm
Brilliant. That is some achievement. Well done.
"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.
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.
#69
dablik
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Posted 09 August 2010 - 09:28 pm
Great job danbara,,,,,well done for stickin at it 
Bigred mk1 R1 Calipers- Braided lines- Givi wing rack-Crash bungs- Hi vis bullets-PR2's- and a hoot to ride.
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Sorted and on the Road Mick 
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#70
Studley Ramrod
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Posted 10 August 2010 - 07:57 am
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#71
danbara
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Posted 27 August 2010 - 09:40 am
now i need a piece of advice
at what rpm's should i drive it and for how long, since new bearings and stuff are installed so I think it is almost the same as the engine is new
at what rpm's should i drive it and for how long, since new bearings and stuff are installed so I think it is almost the same as the engine is new
#72
dapleb
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Posted 27 August 2010 - 09:43 am
Muhaha.....this has been discussed many times....some will say baby it....come say rag it. Personally I went with the upper end of the Yamaha specs.
EDIT: http://www.carpe-tdm...o...&hl=running
EDIT2: http://www.carpe-tdm...o...&hl=running
EDIT: http://www.carpe-tdm...o...&hl=running
EDIT2: http://www.carpe-tdm...o...&hl=running
"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.
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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