Service advice?

ppgflyer · 09-04-2013, 05:38 PM

Following on from my previous post "hard miss in 2nd gear", which I finally decided was 2nd gear popping out, I removed the engine from the frame last w/e. I was not going to completely strip it down but after seeing a fair amount of carbon on the piston along with evidence of coolant leak in to one of the main 12mm stud tubes I decided to go for a complete tear-down.

The current plan of action will be to replace the damaged transmission parts. Lightly hone the bores. De-carbonize pistons, heads & valves. Make & install coasters. Make & install timing chain adjuster extenders.

Plans for future mod will be air intake modification along with a TFI, already have V&H pipes.

With 40K on the engine what other recommendations does anyone have for maintenance on the engine while it's on the bench? I was thinking of replacing the rings but will probably take some measurements first before I spend the money.

I have a pile of pictures but I'm not sure where to place them for your viewing pleasure, any suggestions?

Greg.

usranger74 · 09-04-2013, 05:42 PM

Sure wish I had you skills.

Post the pics in a place like Photo Bucket and then post the link here.

jandreu · 09-04-2013, 06:40 PM

Dang if your that far into it Thunder Mfg makes a big bore kit for our motors.

**ringadingh** · 09-04-2013, 06:57 PM

Sounds like you have everything covered, I'd probably install a new clutch spring while your in there, since thats usually about the time they start slipping.

**MAS Tequila** · 09-04-2013, 07:28 PM

Go ahead and do the rings.

Each head has two bronze oil screens, replace those.

Check the valve seals.

Remove the KACR's, KAwasaki automatic compression release mechanisms, when they go the head will be trashed.

I'll post some others as they are remembered.

MT

kmaysob · 09-04-2013, 11:19 PM

If your tearing it down, change the chains instead of adding extenders. Like it or not, extenders will effect timing

kmaysob · 09-04-2013, 11:22 PM

Also, lap the valves while your at it

ppgflyer · 09-04-2013, 11:46 PM

My apologies, forgot to mention that I already have a mean streak clutch spring and new s/s braided brake & clutch lines.

MT - remove KACR's ? What happens to them? When you say "check the valve seals" are you talking the cleaning fluid test?

James, I don't think my budget can encompass the big bore kit.

Greg.

**MAS Tequila** · 09-05-2013, 06:23 AM

Quote:

Originally Posted by ppgflyer

My apologies, forgot to mention that I already have a mean streak clutch spring and new s/s braided brake & clutch lines.

MT - remove KACR's ? What happens to them? When you say "check the valve seals" are you talking the cleaning fluid test?

James, I don't think my budget can encompass the big bore kit.

Greg.

The KACR's, when they malfunction, cause the unit to hand grenade, resulting in catastrophic damage to the head. I have never put them back in an engine I've had apart and have never had an issue because of it. This is more of a VROC braintrust recommendation.

As far as the seals, inspect them whatever way works for you. It 's the old addge that if you don't they WILL start leaking.

MT

ppgflyer · 09-05-2013, 04:30 PM

Okay, I finally put my pictures in a google+/picassa album, not sure how to share that so I also put them in my photobucket account.

The link is;
http://s1198.photobucket.com/user/ppggreg/library/

It is password protected, it's my VB user name. (or maybe not - didn't seem to work so I just made it public)

I will be finishing the tear down this w/e as I only have access to the machine shop on weekends when it's quiet. I will post more pictures next week.

Greg.

**HwyRider** · 09-05-2013, 04:40 PM

The password is your username.

ppgflyer · 09-05-2013, 05:22 PM

Yes, but I went back in and removed the password requirement so you should be able to see the album without a password.

davidhollinger · 09-06-2013, 11:36 AM

No way would I want to see my bike torn down like that. It would be like watching my own autopsy! No thanks!
You must be a pretty good mechanic...

1500ccs · 09-06-2013, 12:30 PM

The big bore kit is way too much money for what it provides. Instead of tensioners measure the flex on the cam chains and get new chains if possible. You are going to need to split the cases to get to the transmission - it would be great if you post process/pics on that. You already seem to have a good grip on what you are doing but here's a useful thread on another rebuild if that helps - http://tearitupfixitrepeat.blogspot....aultvml-o.html. Its a carbed 1500 but the motors are almost identical.

ppgflyer · 09-08-2013, 01:45 AM

Okay, second set of pictures are up on photobucket. These are of the crankcase and transmission.

http://s1198.photobucket.com/user/ppggreg/library/

I wanted to split the case a little differently but decided it was easier to take it completely apart rather than try to keep the cylinders and rocker boxes in place.

I will have some tips at the end to help anyone else looking to undertake a rebuild similar to this one.

I will be ordering the required gears and shift fork this weekend, hopefully they will be here in time to start re-assembly next weekend.

Greg.

09-04-2013, 05:38 PM	#1
ppgflyer Member Join Date: May 2013 Location: Los Angeles Posts: 117	Service advice? Following on from my previous post "hard miss in 2nd gear", which I finally decided was 2nd gear popping out, I removed the engine from the frame last w/e. I was not going to completely strip it down but after seeing a fair amount of carbon on the piston along with evidence of coolant leak in to one of the main 12mm stud tubes I decided to go for a complete tear-down. The current plan of action will be to replace the damaged transmission parts. Lightly hone the bores. De-carbonize pistons, heads & valves. Make & install coasters. Make & install timing chain adjuster extenders. Plans for future mod will be air intake modification along with a TFI, already have V&H pipes. With 40K on the engine what other recommendations does anyone have for maintenance on the engine while it's on the bench? I was thinking of replacing the rings but will probably take some measurements first before I spend the money. I have a pile of pictures but I'm not sure where to place them for your viewing pleasure, any suggestions? Greg. Login or Register to Remove Ads
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09-04-2013, 05:42 PM	#2
usranger74 Sr. Member Join Date: Mar 2010 Location: La Vista, NE Posts: 4,060	Sure wish I had you skills. Post the pics in a place like Photo Bucket and then post the link here. __________________ Bill (usranger74) Blake 2016 Goldwing VBA # 1505
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09-04-2013, 06:40 PM	#3
jandreu Sr. Member Join Date: Jan 2010 Location: Makawao, Hawaii Posts: 1,409	Dang if your that far into it Thunder Mfg makes a big bore kit for our motors. __________________ James Andreu '07 1600 Red/Silver VBA Member #1356 jandreu@hawaiiantel.net
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09-04-2013, 06:57 PM	#4
ringadingh Join Date: Aug 2007 Location: Newmarket Ontario Canada Posts: 35,387	Sounds like you have everything covered, I'd probably install a new clutch spring while your in there, since thats usually about the time they start slipping. __________________ 2002 Nomad aka Bountyhunter VBA #27 VROC #18951
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09-04-2013, 07:28 PM	#5
MAS Tequila Join Date: Jan 2009 Location: Psychiatric Ward FL Posts: 3,429	Go ahead and do the rings. Each head has two bronze oil screens, replace those. Check the valve seals. Remove the KACR's, KAwasaki automatic compression release mechanisms, when they go the head will be trashed. I'll post some others as they are remembered. MT __________________ MT 2016 FLHP Psychiatric Ward FL VBA 936 Login or Register to Remove Ads
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09-04-2013, 11:19 PM	#6
kmaysob Member Join Date: Jul 2013 Location: Mesa Az Posts: 290	If your tearing it down, change the chains instead of adding extenders. Like it or not, extenders will effect timing __________________ -RYAN- 2008 Nomad 1600 Blue and silver
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09-04-2013, 11:22 PM	#7
kmaysob Member Join Date: Jul 2013 Location: Mesa Az Posts: 290	Also, lap the valves while your at it __________________ -RYAN- 2008 Nomad 1600 Blue and silver
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09-04-2013, 11:46 PM	#8
ppgflyer Member Join Date: May 2013 Location: Los Angeles Posts: 117	My apologies, forgot to mention that I already have a mean streak clutch spring and new s/s braided brake & clutch lines. MT - remove KACR's ? What happens to them? When you say "check the valve seals" are you talking the cleaning fluid test? James, I don't think my budget can encompass the big bore kit. Greg.
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09-05-2013, 04:30 PM	#10
ppgflyer Member Join Date: May 2013 Location: Los Angeles Posts: 117	Okay, I finally put my pictures in a google+/picassa album, not sure how to share that so I also put them in my photobucket account. The link is; http://s1198.photobucket.com/user/ppggreg/library/ It is password protected, it's my VB user name. (or maybe not - didn't seem to work so I just made it public) I will be finishing the tear down this w/e as I only have access to the machine shop on weekends when it's quiet. I will post more pictures next week. Greg. Last edited by ppgflyer; 09-05-2013 at 04:35 PM.
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09-05-2013, 04:40 PM	#11
HwyRider Join Date: Jun 2013 Location: South Shore, MA Posts: 4,629	The password is your username. __________________ VBA # 02424 VROC # 35971 2010 Nomad 1700 Metallic Diablo Black/Metallic Titanium
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09-05-2013, 05:22 PM	#12
ppgflyer Member Join Date: May 2013 Location: Los Angeles Posts: 117	Yes, but I went back in and removed the password requirement so you should be able to see the album without a password.
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09-06-2013, 11:36 AM	#13
davidhollinger Sr. Member Join Date: Aug 2012 Location: Central Alabama Posts: 2,188	No way would I want to see my bike torn down like that. It would be like watching my own autopsy! No thanks! You must be a pretty good mechanic... __________________ I would be patient, but it takes too long!! David Hollinger 2002 Beige 1500 "Hannah2" VBA # 02195
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09-06-2013, 12:30 PM	#14
1500ccs Member Join Date: Jul 2010 Posts: 87	The big bore kit is way too much money for what it provides. Instead of tensioners measure the flex on the cam chains and get new chains if possible. You are going to need to split the cases to get to the transmission - it would be great if you post process/pics on that. You already seem to have a good grip on what you are doing but here's a useful thread on another rebuild if that helps - http://tearitupfixitrepeat.blogspot....aultvml-o.html. Its a carbed 1500 but the motors are almost identical.
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09-08-2013, 01:45 AM	#15
ppgflyer Member Join Date: May 2013 Location: Los Angeles Posts: 117	Okay, second set of pictures are up on photobucket. These are of the crankcase and transmission. http://s1198.photobucket.com/user/ppggreg/library/ I wanted to split the case a little differently but decided it was easier to take it completely apart rather than try to keep the cylinders and rocker boxes in place. I will have some tips at the end to help anyone else looking to undertake a rebuild similar to this one. I will be ordering the required gears and shift fork this weekend, hopefully they will be here in time to start re-assembly next weekend. Greg.
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