A couple of thousand miles ago I wrote up a how to on tightening the alternator chain. Since then the bike has been going like a purring cat but a week ago I stopped at some lights and accidentally stalled the engine when pulling away. It started up again but had a nasty sounding rattle which freaked me out. I got it the couple of miles to work and decided there and then that I had to take out the engine and operate. After 60K miles I figured it must be about time anyway and quit riding it while it's still running.
Got the motor last weekend after breaking two exhaust studs and an engine mounting bolt. All fusted to ruck!
Not having had any time to even lift a spanner to it this week I'm now about to start on the strip down.
I thought I'd see if could summon on the collective forum brains and see if any of you guys have any suggestions as to what to replace other than the obvious.
This is what I'm intending doing/replacing:

1. All three chains, alternator and CC tensioners and chain guides. (As far as I can make out from the manual and parts catalogue there is no tensioner for the oil pump chain).
2. Oil seals
3. Check oil pump wear and service/replace if necessary.
4. Check clutch wear but I won't replace anything unless it looks a real basket case. It works fine.
5. All gaskets, o rings and general re-assembly items.

I hope I'll be able to get the broken exhaust studs out as there's a good 10 mm protruding. I'll soak the threads with plenty of spray and leave to soak in for a long time then heat up the case, chill the stud end and hope for the best. There's an amazing product which I bought whilst getting the engine out. It freezes parts down to -42 degrees C to shrink them. It sure worked well on some of the really stiff engine mounting bolts.

If any of you guys have some further advice for me over the next few days while I'm doing the deed I'd be most grateful to hear your thoughts.
A good and preferably cheap/reasonably priced source of parts in the UK would be useful to know about too.

I'll let you know what I find in there. Hope it's nothing aweful.

 

I haven't done the surgery but I'd say the UK members like Hawkwind and Sawnee could probably point you in the right direction for spares.
I use these in the UK
www.wemoto.com
or www.davidsilverspares.co.uk (check Google) both are reliable and ship quickly.

When you strip it please tell me if the primary chain repair you did, failed and has caused the grinding ....I'm still trying to figure an alternative.....................

 

Hi Shadow,
Don't worry. I'll be honest. If my repair screwed up I'll come clean. The new noise/rattle seems to come from the top end but I didn't really want to run it much more after it happened so I'm just going straight in there to do what has to be done.
Getting the engine out was a complete pain, only because of the rust on the bolts.
When I worked in bike shops we were all agreed that if we ever bought a new Jap bike the first thing we would do was take it apart and grease every single nut and bolt to make sure it came apart again at some future time when you'd need to do major work. Now I am still thinking that this is a classic example of lack of preservative.
Thanks for the lead on parts dealers. I'll give them a try. I think once I've got my definitive list of parts I'll get quotes from a few different places.
Why is it that bike parts are so expensive compared to car parts? It sucks.

For your alternative alternator chain idea, I'll let you know what's do-able through the sump.
I think photos and some sort of write up of the operation may be a good idea. No one has done a 'how to' on splitting the cases in the forum as far as I can see.
Cheers for your support as always.

 

I'm still trying to find heatproof cable ties, Henry - you think you have spares problems.....I have to buy almost everything from the US and UK, except for a camchain with a link (no case splitting neccessary)

As for the grinding, I would have thought of two areas...
1 The camchain tensioner has stuck(mine did) and the new chain rattled after a week of service !!
2 The repair you did - with the stress on the chain on the alternator (no movement in the tensioner) maybe the extreme pressure caused the C section to move.........sounds logical but if you say it's coming from the top, must surely be no 1...?
Lettuce know what you find, eh ?

Oh and no, I don't think anyone's done a case split on the forum - only resource is the manual, but we all know how accurate that can be..............
I'm not looking forward to removing the mill - she's a heavy old lump...............

 

Hey Pete I posted these up before in another thread , was thinking they may do the job better than plastic?

http://cgi.ebay.co.uk/4-X-20-STAINLE...item3a53cdd856

Henry , a how to on 'Splitting the cases', would be terrific!

I use WEMOTO as they are just down the road from me and can pick the stuff up to save on postage/time. They're pretty good and are a friendly bunch.

Sawnee may be of more help as he lives in Kent , so may know of somewhere more local to you . Drop him a PM .

 

Cheers guys,
This is all useful stuff but I'm too wired to do anything useful today.
My father in law died this morning and I've had one very weird day. Started driving at 03.00 this morning, missed his last breath by two minutes and had four weeping women to prop up for a few hours. When life returns to a bit of normality again I'll get moving and start working on the lump but for now... I'm shagged.
I haven't looked at your link Hawk but just looking at the title I can see you're on to something with the word stainless. S/S ties would be a much better substitute for the HT nylons I used but I'm interested to see what's happened to my repair. I'll photo it and let you know.
As for getting the engine out Shadow, yes it is very heavy. 96 Kg (211.64 Lbs) and don't you just know it when it starts to come free. Mind ya bloody fingers! I used a car jack under the sump and let it down slowly. It takes a bit of jiggling about in the frame to get it to the ground and then you have to lift the bike over it when it's finally down. It's not too much hassle if you've got a couple of pairs of strong arms to help. Don't try it on your own unless you've got a good bike bench to clamp the back tyre and stop the bike moving.
I managed to lift the engine into the back of the car on my own but again, if you can muster help it's a better bet. I only weigh 73 Kg so mind over matter made that happen. Puff... pant...wheeze!
It's still in the back of the car after a week due to lack of time to start the work but tomorrow it's coming out and I'm going to get in there. I'm not going to work for couple of days. My superior half will need some propping up in the next few days and the least I can do is be there.
I'll set up the camera and snap as I go. The 'how to' would indeed be interesting. Wish I had one now.

 

Sorry about your Father in Law, Henry.
Our thoughts are with you...........we just lost a member of the Hurricane section too, only told yesterday (Hardcorp) - rode a 93 model, great guy.

If you can pick up a mill that weighs 50 Lbs more than you do, I'm not going to mess with you....hehe.


HAWK those look like the business ! May have to invest in some......................
THANKS MATE !

 

Thanks for your thoughts. Much appreciated. Death can be a strange trip for the living.

Wow, I'm sorry. I read some stuff by Hardcore. He seemed as though he lived up to his name more than adequately. How did he pass on? My condolences to the brave knight!

Don't worry about messing with me. When I'm not lifting engines I spend most of my time pretending to be a Koala (with beer).

Which part of the world are you from Shadow?

 

Sorry for your loss Henry. I didn't know about it when I ribbed you in the giggles thread.

 

It's a bit off topic, but it's your call as it's your thread................
Hardcorp - Tim Wilkinson ex Gunnery Sgt US Marines, 2 tours to Iraq, 21/2 tours to Afghanistan,(came home early due to wounds) Marine Recon unit (the best they have) and a sniper/HALO Jumper unarmed combat spec, and scuba specialist.recently responsible for correcting the behaviour of some fairly nasty people....having said that, a great guy, family man with two boys, one only 6 weeks old...........friend of mine for the past two years, regular chats on the phone to Georgia.
Died in a car accident on duty somewhere in the US.last Friday..................He designed part of my siggy, and the complete one I use on the CBRJunkie forum too, where many of us have dual membership.A true gentleman and a patriot. I miss him..............

As for me - I live in the land of the Zulu, Kwa-Zulu-Natal in the Republic of South Africa, east coast, near Durban.

And don't worry Henry, when we know you better we'll ALL mess with you..............