892 replies to this topic

[Studley Ramrod]

Those T30's are a challenge to remove, hardest part of the strip for moi.  I bent/twisted a few T30 bits trying to remove mine.  Think I ended up helicoiling one after carefully drilling the bolt out.

 

You will get different sized shells.

[wicklamulla]

i remember Dappers saying he went the whole hog and did the testing / measuring using plasti gauge  (to establish shell size i think?) to get it nigh on perfect.  I know some peeps just sling in a used crank and don't seem to consider too much when it comes to replacement shell sizes and maybe the get away with it. Cliff i have a fair sized (messy) garage and am hopefully building anudder outbuilding this year measuring approximately 24' x 13' which will house some of my tree surgery kit and a couple of bikes, hydraulic lift bench etc.  Following yer fred with interest blood.

Edited by wicklamulla, 09 June 2019 - 11:07 pm.

[madmopedracer]

its a scientific fact that the size of your shed is inversely proportional to the amount of crap you put in said shed

[dablik]

Those T30's are a challenge to remove, hardest part of the strip for moi.  I bent/twisted a few T30 bits trying to remove mine.  Think I ended up helicoiling one after carefully drilling the bolt out.

 

You will get different sized shells.

 

Good to know about the T30 torx bits, will drill them out.

 

I know you can have different sized shells across the 3 mains, but i have 2 colours on one bearing, will check it all out later, prolly start a new thread re all that stuff to keep it in one place..

i remember Dappers saying he went the whole hog and did the testing / measuring using plasti gauge  (to establish shell size i think?) to get it nigh on perfect.  I know some peeps just sling in a used crank and don't seem to consider too much when it comes to replacement shell sizes and maybe the get away with it. Cliff i have a fair sized (messy) garage and am hopefully building anudder outbuilding this year measuring approximately 24' x 13' which will house some of my tree surgery kit and a couple of bikes, hydraulic lift bench etc.  Following yer fred with interest blood.

 

I got the dappers thread bookmarked wicki as it's a good reference, still a bit of a mindfook though, my plan is to measure and replace if needed, no point getting this far and not doing it, having said that though i think these motors will tick along just fine if slightly out of spec but not knowing enough about engines i'll go ahead and measure up. Sounds lovely Ken, when you've built that outbuilding you'll just have to destruct one of ya bikes matey, the 9r barrel job maybe ?

its a scientific fact that the size of your shed is inversely proportional to the amount of crap you put in said shed

 

[dapleb]

Only seen shells in equal colours dabbers. I guess if journal in one journal half is diff to t'other half its possible!! Else they had colour blind eejit in production lion loike me. So annoying they used colours....on shells...that fade...and you can't see. Try the photo and zoom trick, works well.


The big end shell sizes also colour coded can be calced/checked from the numbers stamped on caps and journal stamps....can't remember if same can be done with other numbers for main burrings. Not got oubt with me to jog memory. Will try look later.

T30 on balancers is booger. Need great fit and Tbar. Can use MILD heat but small o ring on balancer, no melty.

Keep going dabbers. When you are this far in there is no point on cutting corners!!!

[dablik]

DO NOT USE NUMBERS QUOTED BELOW AS REF FOR YOUR OWN SHELLS, NOWT IS CERTAIN.

 

It's all in the Haynes ow to measure up daps, a bit confuzzling but i have the general idea, am going to plastigauge as well, it's funny about the different colour shells innit, i thought maybe i had goofed up and mixed left with right shells but after just looking at wot i marked up i think someone was in here before, these are me findings

 

Left bearings   Upper = 121A = Red/Brown

                        Lower = 141D = Green !!!

 

Middle "           Upper = 121A = Red/Brown

                        Lower = 121A = Red/Brown

 

Right "             Upper = 141D = Green!!!

                        Lower = 121A = Red/Brown

 

So looking at that you can see i have a Lower on Left side with a Green and an Lower on Right side with a Red, and i know that the shells were marked up with permanent marker before i removed them from the journals so that would discount mixing up lefty and righty after the cases were split...

 

Different colours would'n make any sense though me thinks as the differences are in thickness of the shell bearings !

 

Tried a little heat on the Torx but did'nt keep it heating long at all, dont think both me T30 bits were a great fit either,drilling shall commence.

 

Shall crack on..

Edited by dablik, 17 June 2019 - 01:43 pm.

[dablik]

Hurrah a few dry hours today...woopwoop

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That's th elast of the gubbins out now.

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Torx bolts were well stuck, looks like Red loctite on em, input shaft torx bolts (staked) came out easier than the balance shaft bolts which i need to drill through and retap.

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[Studley Ramrod]

Good job mucker.  

[ramo]

you da man Cliff

[Favs]

Yahoo

[dapleb]

Easy bit done dabbers. !0)

[wicklamulla]

don't mix up all those parts lad!

[dablik]

Easy bit done dabbers. !0)

 

I dunno daps, them blinkin Torx bolts on the balancer shafts, right pain up the jacksie, drilled the heads off to get the shafts out, now i've drilled bang down the centre of screw so i can get an extractor in proper and good but those little bassads aint moving, they only get torqued to around 10nm but ya can see the red shoite in the pic, looks like a drill out an a helicoil.

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Measured up the side play on the Big ends, 0.20mm so about bang in the middle of spec (0.160-0.272)

Those marks on the top of the cap nuts, do they denote anything or is it just the type of nut !!

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About to plastigauge the Big ends then got showered on so tomorra and also plastigauge the crank bearings, cant be arsed now me belly is full of food.

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Still waiting on some bits for the die grinder as wrong shaft size sent, dont think the angle grinder cutting blade will quite fit to chop the rotor off,maybe, will see in the morning.

 

Another thing i noticed inside the crankcase, wot ya think !!

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Lets see if the numbers clearer.

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[Studley Ramrod]

Pretty sure they're just casting marks.

[dablik]

Pretty sure they're just casting marks.

 

Think you may be right, had a lot of them on the 9r's camshaft caps iffin ya remember, hope so anyway

[dablik]

Web numbers of skipped shaft....new crankshaft numbers 22 222 so i dont get confused lookin back at this post

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Crankcase numbers

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Righto, daps just for you mucka, in your very very very very old post you said you had only seen one (yours) of these endangered species.

Cap rod number is 5, summit else is scribbled before and after, looks like A after the 5, presume it's the # 5 i'm using, both caps same number.

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Just done the calcs for bearings and it would appear wot i though was Red previously on the mains is likely Brown now fookin silly system..

Will post up me reckoning at some point for a homework check.

Edited by dablik, 13 July 2019 - 10:08 pm.

[dapleb]

Hmmmm will need to dig out me notes or old post somewhere. I wrote it all down as knew I would forget....now just need to remember where I wrote it....

Anyways, the cap numbers are used to calculate the shell sizes. You subtract the crank web numbers from big end cap number to give you a number that relates to the shell colour code!! Summat loike that. Not got Haynes or oubt useful with me.

I think you can do the same with main burrings but again can't remember exact details. I def wrote destructions down either ear or in me tdm book.

So, check to see if you can see colours on big end shells...then double check by calculation using crank web numbers.

I see your crank webs look like we're machined with a spoon too...they all look like that.


Agree with SR, the crazing you have are just casting marks.

Can't remember any loctite on balancer bolts.

[dablik]

Daps dont go looking it's all here fella post # 10.

Edited by dablik, 15 June 2019 - 08:31 pm.

[Favs]

Cliff watched this Partzilla vid? I'd be suprised if Yamaha had changed the way they do things.

 

https://www.youtube....h?v=wpnllgm3e1I

 

Never mind you got the info........

Edited by Favs, 15 June 2019 - 08:33 pm.

[dablik]

Cliff watched this Partzilla vid? I'd be suprised if Yamaha had changed the way they do things.

 

https://www.youtube....h?v=wpnllgm3e1I

 

Cheers Al,  doubt it also matey, watched a cupla his vids this week, it's all in Haynes and daps post linked above.