71 replies to this topic

[danbara]

When mine Mk1 run out of oil it started producing knocking and rattling sound what i first thought was dry valves or camshaft. but i was wrong because after some time it started again.

so now i have to strip the engine to small bits and pieces and identify the level of damage on crankshaft, piston rods an bearing.

I'll post some pics of the procedure


p.s. it is my first engine rebuild but I hope that I will manage it with help of a service manual .

any tips or tricks regarding this process is very welcome!!

[dapleb]

Good luck it is quite straight forward but time consuming task.

My best tips would be:

Very carefully doument the dismantling (time invested here is easily repaid on the rebuild). Photos and video help. Including wiring and tube routing before removing enjun.

Research on Carpe before you embark so you are aware of the costs involved and the likely problems.

Take your time and pay attention to detail.

Inspect and measure everything very carefully.

You might find it easier (and cheaper) to source a replacement

[ChrisG]

Theres a thread in the knowledgebase with a load of photos of one of Tonydevils rebuilds that is worth a look. Agree with dappers about cost though. Gaskets and seals are flipping expensive before you even get on to replacement parts, so try and price it up first and compare to replacement engine prices, though you could end up with someone elses problems that way. It's an interesting learning experience though. Good luck.

[MadAd]

It's good that you caught it befor it got to the same point as mine!! Siezed!!
I got a gasket set of eBay for a bit over £70 inc p&p.
The big end shells, main shells and rings are costing about £130 from Fowlers
I also had to shell out for a crank and rods but it still worked out cheaper than any of the seccond hand motors I could find!!

[danbara]

engine would cost me around 1000 euro or more since i live in bosnia and we have to import it, and new parts from yamaha dealer are 250, gaskets, new bearings plus 50 euro for crankshaft repair if it is needed.


what damage to expect?

it starts fine and runs good in neutral but when i rev her it starts banging somewhere and knocking



p.s.
I can't see pics on tonydevil post

Edited by danbara, 14 May 2010 - 07:33 am.

[MadAd]

It sounds like your big ends, mine was the same and then siezed!!
I have striped my engine now and looking at things it might be posible to change the big ends without striping the engine, if you take the exhaust, sump and the oil strainer part you can see the big ends through the gap.
I have not tryed this myself so can't be sure it will work.
Best of luck with it!!

[danbara]

first few steps have been made

just to show u what we did i am posting these pic





that's my cousin ( expert mechanic - lawyer by trade) hehehe doing some carb dismantling






these are first few parts that has to be removed





let the oil go out




from other perspective





engine is out ( that was quiet tricky since we didn't have any kind of jack to hoist the engine so we used an old tire )





final result

Edited by danbara, 20 May 2010 - 07:50 am.

[danbara]

@ dapleb

u offered me pics of engine strip and it would be lovely if u could post them here

thanx

[dapleb]

Okey dokey. Let me know what part of the many 1000's you want a picture of?

If you want a guide on how to do a basic top end removal then I would ask Tony to get the pictures put back in his thread. If you are stuck on putting something together or need detailed pics of where/how components go then lettuce snow which bit and oil dig up a pic.

[Studley Ramrod]

You may need a few specialist/custom made tools. Clutch holding tool, bearing pullers and whatever else Brianvg and others can think of.

I think Brian also bought quite a few new seals from an Eskimo, err, I mean a yamaha dealer, along with gaskets and bearings etc.


EDIT: Looks to be a nice bike from what can I see

EDIT2: Just noticed your rear shock has a blue spring. Is it a standard shock ?

Edited by Studley Ramrod, 20 May 2010 - 02:32 pm.

[danbara]

tnx for the link with pics and parts.

the thing is how much will delivery cost since I am in middle Europe and this is USA but it is great

p.s. the pics are great.

did u have to change crankshaft as well ?

[danbara]

removed head and cylinders block, pistons are out

first piston big end have some slack.

have to take crankshaft out to asses the damage


I hope I would not need to change crankshaft and piston rod

d..... it

[dapleb]

Heya,

From your PM you wanted pics of good and bad cranks and rods.


Good:
 crank_good1.JPG   58.03KB   33 downloads
 crank_good2.JPG   71.23KB   30 downloads
 crank_good3.JPG   46.44KB   35 downloads

Not so good:
 crank_verybad1.JPG   14.08KB   43 downloads
 crank_verybad2.JPG   94.97KB   42 downloads

If you want a picture of something more specific then take a pic of what you have/want and I will try and find a close comparison picture.

[danbara]

I'm having trouble taking magnet of.

i tried with classic puller but no movement, so i decided to build something like brian did, but also had no success wit it

the bloody thing just wont come of.

any piece of advice????

[dapleb]

Oi managed to distort me biggest 3 legged puller gettin one off. The others have come off without much problem.

Maybe a little bit of carefully directed heat? Not sure if this can poop the magnet though.

[Oil patch]

Treat the magnet with respect as they can be demagnetised by knocking, I mean sharp blows with hammer, or by applied heat.
all the best.