Finally tore down my engine(pics)

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 6:56 am

Finally got around to it,I was pushing it as far as it would go,last week I was rippin around and she got stuck on 3rd gear,I already had no 5th so I decided to tear it apart Heres what I found.main shaft 5th & 3rd excessivly worn where they mate up together.

also some washers in the wrong places on both shafts.the cases are a little hogged out

one of the little spring & pushers on this shift linkage thingy was stuck down in the little hole,maybe why I couldn't get out of 3rd?

The shift drum & forks look good to me

Cylinder,Crank & piston all look good,

Its got a wiseco sticker on the swingarm,is it a wiseco piston?if so shouldn't it have some holes drilled somewhere?thats all the pics I had a chance to take,my right seal was on crooked,my clutch basket is severly grooved,the inner hub has some grooving on the six bolt things but looks usable,lets here what you got to say.

dannygraves · Post by **dannygraves** » July 5th, 2007, 7:05 am

sorry dude, that remind me of my basket case when I got it, only worse.
Yes, thats a wiseco. Some builders don't drill holes and don't releive the bridge, they are real bright!

Well, it looks like it is going to force you to do a full rebuild, so dig in!

Post by **AlisoBob** » July 5th, 2007, 7:10 am

Is that carbon, or is the compustion chamber all dinged up?

Looks like some debris from the crankcase went up through there..

Have a better photo?

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 7:14 am

AlisoBob wrote:Is that carbon, or is the compustion chamber all dinged up?

Looks like some debris ( or a cir-clip) went through there..

Have a better photo?

Its carbon,I ws expecting it to be worse

dannygraves · Post by **dannygraves** » July 5th, 2007, 7:14 am

yeah, that head looks way dinged up to me. Thats just an excuse to send it out and have it reshaped (and send the cylinder for porting work too) 8-)

Post by **AlisoBob** » July 5th, 2007, 7:15 am

Do you have a shot of the underside of the piston?

dannygraves · Post by **dannygraves** » July 5th, 2007, 7:16 am

look at the color of the top of the piston too, I hope thats just optics on the camera!

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 7:20 am

dannygraves wrote:sorry dude, that remind me of my basket case when I got it, only worse.
Yes, thats a wiseco. Some builders don't drill holes and don't releive the bridge, they are real bright!
Well, it looks like it is going to force you to do a full rebuild, so dig in!

Heres my plan,new gaskets,seals & bearings/New Clutch Basket/New 5th & 3rd main shaft gears,new clutch discs,plates,new stator plate-mines cracked/Do cases usually get hogged out like that or is something wrong there?When you say relieve the bridge you mean round off the edges?

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 7:22 am

AlisoBob wrote:Do you have a shot of the underside of the piston?

never took it off the con-rod yet will do tonight

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 7:23 am

dannygraves wrote:look at the color of the top of the piston too, I hope thats just optics on the camera!

Its black from carbon,shouldn't it be like that?

97af · Post by **97af** » July 5th, 2007, 7:26 am

Maybe its the picture but that cylinder sleeve looks really thin.
2MM over maybe?

Post by **AlisoBob** » July 5th, 2007, 7:29 am

kkvslayer wrote:Do cases usually get hogged out like that or is something wrong there?When you say relieve the bridge you mean round off the edges?

Ive never seen cases like that off a 500. You need to find the source of whatever went though there... Perhaps the last owner ( who put the tranny back together incorrectly) had a major issue like a shattered piston and didnt bother to reblend the cases when he rebuilt it.

"Relieving" the bridge is taking a small amount of material off the exhaust bridge to prevent it from swelling out inth the path of the piston.

If you have a factory service manual, all the bridge deminsions are in it.

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 7:31 am

AlisoBob wrote:
kkvslayer wrote:Do cases usually get hogged out like that or is something wrong there?When you say relieve the bridge you mean round off the edges?
Ive never seen cases like that off a 500. You need to find the source of whatever went though there...

"Relieving" the bridge is taking a small amount of material off the exhaust bridge to prevent it from swelling out inth the path of the piston.

If you have a factory service manual, all the bridge deminsions are in it.

So are they still usable?

Post by **AlisoBob** » July 5th, 2007, 7:34 am

Sure... they just need a little TLC...

Post by **AlisoBob** » July 5th, 2007, 7:37 am

97af wrote:Maybe its the picture but that cylinder sleeve looks really thin.
2MM over maybe?

Good call Mike.... notice the reveal on the combustion chamber too.

KKV, I know your in the middle of "Nowheresville"....

How close is the nearest machine shop?

( or UPS depot?......

)

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 7:38 am

AlisoBob wrote:Sure... they just need a little TLC...

Proessional TLC?What should I do?

dannygraves · Post by **dannygraves** » July 5th, 2007, 7:57 am

Here is a little write up on releiving the exhaust bridge. itf for an aircooled 350, so the dimensions are a little off, but gives you an idea.
http://www.aftershockmotorsports.com/350rebuild/

Post by **AlisoBob** » July 5th, 2007, 7:59 am

kkvslayer wrote: Proessional TLC? What should I do?

Naaa...... A little #100 "Wet / Dry " sandpaper and some sweat and she be lookin' good in 10 minutes....

dannygraves · Post by **dannygraves** » July 5th, 2007, 8:02 am

kkvslayer wrote:
dannygraves wrote:sorry dude, that remind me of my basket case when I got it, only worse.
Yes, thats a wiseco. Some builders don't drill holes and don't releive the bridge, they are real bright!
Well, it looks like it is going to force you to do a full rebuild, so dig in!
Heres my plan,new gaskets,seals & bearings/New Clutch Basket/New 5th & 3rd main shaft gears,new clutch discs,plates,new stator plate-mines cracked/Do cases usually get hogged out like that or is something wrong there?When you say relieve the bridge you mean round off the edges?

A friend of mine just rebuilt a blaster and the cases looked like that because the rod bearings were toast and the rod ended up rubbing the cases. we used a little 3m abrasive (scotch brite green) wheel and smooth it out. When grooves like that are made metal shavings will hide out in the grooves then bounce around the motor. as long as you get them smooth you should be fine.
Use carb or brake pars cleaner to clean off the top of the piston and you should see some numbers. if it says 2.00 you need to resleeve or get another cylinder.

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 8:02 am

Cool,so I just gotta smooth em out?

Post by **AlisoBob** » July 5th, 2007, 8:06 am

Here's the page from the manual...

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 8:08 am

AlisoBob wrote:Here's the page from the manual...

So this is done with the same wet/dry sandpaper?

Post by **AlisoBob** » July 5th, 2007, 8:09 am

kkvslayer wrote:Cool,so I just gotta smooth em out?

Yup... the crankcase is a pretty stressed area... Any gouges like that are stress risers, where problems can develop.

Its best to sand them out, and blend it all back in.....

BE CAREFUL NOT TO COMPROMISE THE GASKET MATING SURFACES!

Easy does it, man!

Post by **AlisoBob** » July 5th, 2007, 8:12 am

kkvslayer wrote: So this is done with the same wet/dry sandpaper?

It can be, but most folks use a die grinder with a sanding roll on it.

Lay a straight edge ( vertically ) over the bridge... and look for any light passing beneath it.....It may be relieved already...

0.08mm isnt much!

kkvslayer · Post by **kkvslayer** » July 5th, 2007, 8:17 am

also I forgot to mention there was no ball bearing in the clutch assembly

BannedCR500Riders.com

Finally tore down my engine(pics)

Finally tore down my engine(pics)