Ethanw99 Occasional Poster

Super Cool Since: Feb 2013 Locale: Seaford Va Postings: 6 Thanks: 0 Thanked 0 Times in 0 Posts

Re: Jumped the gun on this one, time for a tear down. UPDATE #1



I took the afternoon off work today because of sinusitis which sounds completely fake but its actually a real disease. I have some time before class to post more of what i've done.



Thank you to everyone who's responded with advice. I'm sure I'll need plenty more before this is over.



The radiator and fan hardware was well rusted and corroded. I'll just have to remove the whole thing as an assembly and deal with that later.







I'll be sure to not over tighten these.







I got my first look at the cams and they don't look too bad. No obvious scoring or discoloration. That's one less thing to worry about at least.







The threaded holes to the leaky valve cover bolts also looked good. Hopefully replacing the bolt gaskets will solve the leak. If not, I can easily install some stainless helicoils and snug the bolts down. If worse comes to worse, ill throw some #2 permitex on them.







The left side also looked good from the initial inspection.







Time to pull the carb and get the cams out.



I noticed one of the tubes coming out the top of the carb was plugged. I'm assuming this is the vacuum line. It starts to make sense when i found that one of the lines coming out of the petcock also disconnected.



The guy I bought the bike from gave me a bunch of spare parts from the previous owner. There was a bag with a plastic cap, an aluminum square plate with four holes in it, and a matching gasket and bolts. Im assuming its a manuel petcock blockoff plate



I wonder why he didn't install it? I guess I might as well when I put the carb back on.



Here is the plugged line.





A better view to where it comes from.





Removing and labeling the push pull lines.





It'll definitely need a thorough cleaning.





I didnt take any pictures of the disassemble and cleaning of it. There's plenty of information avalible for anyone who needs to know how to clean it.







I soaked all the non rubber and plastic parts in acetone for a while and scrubbed all the extra carbon buildup off of it. It wasn't bad at all.



I also found that the needle was shimmed with one washer and the hole was drilled out as required for the $0.22 mod.



It cleaned up very well.





I also replaced the hardware with new stainless washers and anodized SHCS's







I pulled all the fairings off and set the damaged ones aside for sanding and re rattlecan-ing.



I'll deal with that later.



I also pulled out the air filter. It was FILTHY! There was all kinds of debris in the

airbox. Hopefully a new filter and some cleaning will go a long way.



Could this color be because dirt stuck to the oil the filter was treated with?





Time to pull the cam caps and take the cams out after I measure the initial valve clearence.



This is where the project started becoming more hands on and I slacked with taking pictures. There's plenty of good tutorials online for preforming valve adjustments.



Valve clearance



For my intake valves , I measured the clearance to be 0.005 (in) for both of the valves while the engine was at TDC. This is still within specification but ill probably want to open up the clearance to give them more room to shrink over time. They both had #260 shims.



Again, the engine was at TDC with the cams pointing outward front and back.



The exhaust valves were a different story. I struggled to get my 0.0015 feeler gauge under the right one and could fit nothing at all under the left. I could rotate both shims but it took a significant amount of effort. This alone was reason to pull hte whole top end apart and see what was going on in there.



New oem gaskets for the valve cover and upper cylinder are on the way.



When i was removing the cam caps, I got excited and I forgot to remove the cam chain tensioner. Hopefully this wont cause any major problems, I took it off right after I removed the cams. I dont have any pictures of them but they looked really good. No scoring or discoloration at all in the seats. Hopefully this means the bike was never run low on oil.



Time to remove the top end.



I mainly followed the Clymer manual for this part.



I pulled off the coolant temperature line and was somewhat surprised when there was no temperature regulator in it. It would make sense to remove it while installing the Thermobob though. Can anyone confirm this? There was only an o-ring sealing it.







Next i removed the starter to get to the oil supply pipe and to just make life easier.



Anyone know where this oil could be leaking from? I'm still thinking its the lower banjo bolt.





After removing the two bolts and the electronic connection, a couple gentle taps with a dead blow and the starter popped off of the left side case no problem.







The next step was to remove the banjo bot and the TWO WASHERS on either side of it. They're easy to lose. I also took off the two acorn nuts from the bottom, back side of the head.





in this picture it looks like the oil may be coming from my lower cylinder.





Dont forget these two bolts up front!





For some reason, this second one is a SHCS





After working to get the bolts that go through it out, it came off with a couple taps from a deadblow.





After initial inspectiin, the exhaust valves looked like they had uneven wear on them. I'll have to do something about all that buildup. Is this from burning oil









The piston didn't look too great either, but ive seen pictures of worse on here.





Ive got some cleaning to do! This is it for this update, I have to go to class.



If anyone sees anything alarming please let me know! My knowledge of engines is limited to replacing the doohicky and impeller shaft on an 05 KLR (after I over tightened the shaft and snapped the end off...)



Now im the proud owner of 1/4 inch and 1/2 inch torque wrenches.



You learn from your mistakes I guess. Hopefully being active on this forum will save me from a similar headache. Thanks for all the advice so far!