Bugger... highside is Bugger #4...

well after work today i went up to my bike hit the start and it fired up instantly... but there was a loud nocking noise coming from the engine... sounds like a big end bearing failure... F**K!!! This is really starting to get on my tits something proper now, going to call a garage tomorrow and get a quote for doing the work... not doing it myself i just want the thing fixed now and i don't have the space/time to do it properly! Really dejected bc everything that i've done seems to be working perfectly but one stupid thing has completely ruined it all... bummed out something royal, and don't have a clue when i'm gunna be able to afford to get it sorted...
a very pissed off
Geo

Oh man. Get the motor out, and get it over to Hullavington. I've been told they're really cheap, and do a pukka job. So close, but no cigar yet... :(

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Originally Posted by Mark_Able

Oh man. Get the motor out, and get it over to Hullavington. I've been told they're really cheap, and do a pukka job. So close, but no cigar yet... :(

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had a google of the mini-moto guys in Hullavington and from their website it looks like they deal exclusively with mini-moto racing am i missing something here? or got the wrong place? :3 don't want to go to the hassle of getting the thing over there if i'm at the wrong place

Give them a call.

Slight change in plan, Jaydee has offered to strip the engine so that i can send the crank off the PJME to be rebuilt, I dropped the engine back out the other day but I'm now having problems finding a way to get the engine up to his, if anybody in/around Salisbury could give a hand, it'd be much appreciated and there would be a pint or two in it for you of course! If you could then just send me a PM so we can sort it out, thanks in advance (being hopeful here)
Geo

Right due to not being able to get the engine up to Jaydees I decided to have a crack on my own and see what happened! Got the clutch cover off and cleaned out the remaining oil, got the clutch/balancer gears/tacho drive etc. off no worries then moved over to the flywheel which proved a bit more of a problem!
I had to get the flywheel nut off which meant i had to stop the flywheel/crank from turning but didn't have the stupidly overpriced service tool from Aprilia! TO THE INGENUITY GIRAFFE! I had a bit of a think and decided it would be easier to stop it turning crank side rather than flywheel side, so i thunk and i thunk and eventually came up with this...
http://i267.photobucket.com/albums/i...6-08200438.jpg
I used a bit of nylon cord i had to weave through the small end of the con-rod around the cylinder head mounts on the crank case, i tied it up tightly while the crank was at the bottom of its rotation so that when it tried to push up it held in place. Pretty good eh?! :p Anyways i used the same method when tightening up the flywheel puller nut and had a very brown moment when it came off because it made a noise very much like something breaking! but can't see anything amiss so i will assume it was just the noise it makes when it comes off!
At this point i had a look over the stator and it looks like its been gouged at some point and has a nasty gash on it, must have been like that for a while but think i may replace it just for peace of mind, provided they aren't too expensive.
got that off and then removed any remaining gears and clips then got to work on the crank case bolts, i had already figured out that the last person who did anything on the engine had an OBSESSION with locktite! I have yet to find a single bolt on the bike that hasn't had the locktite treatment! Had to use a touch of lighter fluid and a socket extension on the end of an allen key to budge them! Got them out eventually and then gave the crank case a bit of a tap with a rubber bammer and the case halves came apart like a dream, I immediately understood what people mean when they say "There is nothing to these engines" its absolutely unbelievable how simple they are...
I haven't yet been able to get the crank out though. I've tried a few things but don't want to go trying to brute force it out unless thats what I'm supposed to do! I had a nose in haynes and it just says "press it out" just wondering if anyone could enlighten me here, had a quick google but didn't turn much up.
Geo

the output shaft is simply stuck in the inner race of the main bearings, you can GENTLY heat up the casings with a blowtorch as youre going to have new crank seals.......
the give the end of the output shaft a tap with a block of wood, dont damage the threads tho. the crank will come out, dont let it drop on the floor.....

someone may have used "Locktite bearing seal" tho if theyve been that keen with the thread locking compound.....

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Originally Posted by jonnydangerous

the output shaft is simply stuck in the inner race of the main bearings, you can GENTLY heat up the casings with a blowtorch as youre going to have new crank seals.......
the give the end of the output shaft a tap with a block of wood, dont damage the threads tho. the crank will come out, dont let it drop on the floor.....

someone may have used "Locktite bearing seal" tho if theyve been that keen with the thread locking compound.....

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Will have another go at it tonight, I don't have a blow torch but will heat it up a bit with a hot air gun and see where it gets me, got new crank seals so not worried about them.
Thanks Geo

if you can get the crank out with the bearings thats ok, or the bearings may stay in the cases, either way is ok......
seeing as youre replacing bearings and seals you may be able to heat the casings and tap the bearings to get it all out rather than possibly damage the thread on the crank webs
once the carnk is out you can take the bearings off, or send it like that for PJME to take bearings off.

Could you put in the oven?? Gas 9 15 mins should expand the cases.