Time to Split the Cases

[Florida 393]

BTW, I'll have John up there as soon as possible. I forgot he and Daniel are your designated emergency wrenches.

Bill

[ossagp1]

What do you mean you can't get the bearings out??

[crfjedi393]

Originally Posted by ossagp1

What do you mean you can't get the bearings out??

Maybe need a special tool or something? I'll have to take pics to show you.
We hammered the main bearings and the countershaft bearing out with a brass rod. No problem. Very unsure about some of the others.

[crfjedi393]

Originally Posted by ossagp1

What do you mean you can't get the bearings out??

I'm simply afraid of damaging the case. If you have a cool suggestion I'm all ears.



Bike looks funny stripped down.

[mxmama393]

_____________________-





Even though I hardly know what I am looking at... those are some great pictures, and this is very educational for me as well. Thanks!

[char393]

ACK!!! Nekkid Bike!!!



Piston and stuff come in today Jedi?

[crfjedi393]

Originally Posted by char393

ACK!!! Nekkid Bike!!!

Not for long. Parts came in.





I got really busy and forgot to take some pics when I should have.
But here's a few.

Oil Pump.



Fits together like this.



And goes here.



The new crank didn't come with a Woodruff Key so I'm using my old one. I stood it up just to make it more visible.



The other side.



These gears only go on one way.

[crfjedi393]

Here's where I got involved and forgot to take pics. Sorry! I'll just pic up where I remembered.

The kick starter assembly is a little cantankerous.(upper left) I wrestled with it more than once. Getting the clutch buttoned back up here.





Making progress.





This little guy KICKED MY BUTT!!



Be sure to cover the opening over the crank with something!



Here is the circlip just before it bounced off of two walls and my right thigh. I was SOOOOO close!




I heard it tinkling around on the floor but never found it. It was moving at a pretty high rate of speed. I'll worry about it tomorrow.

[RMudslinger 250]

Hey this works for me take a small flexable magnet like the ones people stick on there fridge and lay over the side of it once you get it started and most time will prevent loss trickey little devils arent they...

[crfjedi393]

Thanks for the tip!

[RMudslinger 250]

Ino this is off subject but did you ride last man standing seen picture on your profile man that is one tough race. Love to try that.....

[yz250guy]

VERY NICE Photo journal Jedi! Me likey! (Wait, that sounded WAY too much like Char! DOH!)

[crfjedi393]

Originally Posted by RMudslinger 250

Ino this is off subject but did you ride last man standing seen picture on your profile man that is one tough race.

That's me in my sig but LMS is too tough for me! I've ridden there but didn't race that race.

[RMudslinger 250]

I watched on t.v. man that is wild David knight is smooth. I am trying to go to Loretta Lynns this weekend GNCC love that stuff.Got 3 friends ride quads in GNCC. Any bodt else out there going?

[YZalltheway]

i like your saftey wire thing to keep the gears in place, i wish i would have thought about that when i was rebuilding my kx100. i split the cases and all the gears fell out.
why didnt you just heat up the other side of the case with a blow torch and then hit it with the dead blow to take out those bearings?? wow that piston is weird ive never seen one that thin

[crfjedi393]

Originally Posted by Kxalltheway

why didnt you just heat up the other side of the case with a blow torch and then hit it with the dead blow to take out those bearings??

It's called lack of experience. But I'll remember that next time. Thanks.

Still makin' progress.


You need to be VERY patient when sliding the cylinder down over the piston and rings.



Ready for the head.



Setting the timing. The piston must be at TDC with the came lobes pointing to the rear and these two marks on the cam lining up level with the side of the head. There is also a mark on the lower right side of the engine that is nice to check out. No pic.



Last cover to go on. Just need to clean off the old gasket.




Ran out of time for the night. Maybe I can finish it up tomorrow night.

[mxmama393]

man, your stuff looks really clean Jedi. I know that is really important when doing something like that. But its easier said than done.


Also, good job on the pictures, with the FEW things I have done to my sons bike.... I realize dang, that would have been a good picture. You really did good if you were able to keep my attention this far!


Thanks for the lesson!

[ossagp1]

Jedi
sorry I didnt get back to you sooner. all you have to do to get those bearings out is heat the case. i do it with a heat gun and tap the backside with a plastic mallet. On something where they have been in there a long time I warm it and tap,,if it doesnt work just smack the case down on a phone book after it is warm. more fun than finding my bearing puller. That way they can be reused more often than with the puller.

[YZalltheway]

[QUOTE=crfjedi393;464898]It's called lack of experience. But I'll remember that next time. Thanks.

wow i thought your were pretty experienced in this stuff... i rebuilt my kx100 by myself and im 15... but i had all you guys here helpin me out , it it wasnt for your help jedi i would probably still be looking for that view glass

[crfjedi393]

I'm having computer troubles now but the bike is up and running.
Racing this weekend.
Life is good.

I'll post the final pics and stuff when the weekend is over and I can Iron out the computer.