another rebuild

[suzuki0702]

well the title says it.. i need help splitting my cases! ive never done it before, the farthest ive been into this motor is the topend and the clutch...the clymers manual just sucks because its step by step shit is garbage..atleast on the clutch replacement...is it hard? how do i get all the crap off hte bottom so it doesnt go inside? how do i find how im getting water in the lower end? seals, orings? what do i need to do to get the cases apart? this is what i want to replace while im in there..

 

the shifter bar

all seals and orings

crankshaft

 

when i take it apart are springs and shit going to fly out at me? please help thanks guys

[PassionRE]

Its really not that tough. If you have even moderate mechanical skills you can handle it with good advice. You waterpump seal is probably bad if your getting coolant in the bottom end. What other symptoms make you think the bottom end needs rebuilding? If you decide to go in to the bottom end, just give me a call and Ill walk you through it.....Jim

[suzuki0702]

maybe these picks will help, i can feel where the connecting rod would meet the bottom of the case, it feels like it gouged some metal out as if it went further down then it was supposed to..

this is the side all of the problems are on, the piston is dented on the bottom and worn a lot more on the top

here the connecting rod is scored

cant figure out the milky stuff? obviously its water and oil but wheres it coming from? its in both sides of the crank casing

[fast500#12]

look's to me like it's a head gasket or a base gasket there should be no oil in your crank case if there is then your right crank seal let go in which case you still need to split the case. it's not hard if you do a top end you can split the case. the kick starter is the only thing that i had to mess with for a while .

[Wallrat]

Dude don't worry its cake. You kinda gotta jump around in the clymers but it works. Basically you gotta remove the stator and all that crap from the left side, then the clutch, kickstarter, primary gear, etc. from the right side. Once you get there, you just unscrew 10 bolts, and at most, give a little tap to the cases with a rubber mallet while pulling em apart. If you've got the case sitting bottom side down on a workbench, then nothing is gonna spring out. Really the cases are surprisingly empty. All that's in there is the crank and a couple rows of gears that make up the tranny.

 

At that point just pop out the crank (I'd replace it but that's up to you), pop out the tranny pieces, replace the oil seals and pop it all back in. At the very least you should Mic the crank to see how worn it is and if its still in spec. Anyway, then you slather on some yamabond #4 and stick the cases back together. Then its just a matter of doing everything in reverse.

 

If you keep your parts seperate it'll be super easy. I used zip-loc bags and labelled each one with what part it went to. All the bolts, springs, and small parts went into the bag, and then all the bags went into a milk crate. The larger parts are easy to identify, especially if you do the repairs quickly and its only been a day or 2 since you pulled it apart.

 

While you're in there, you might consider replacing:

Crank (hell why not drop in a +4)

Shift forks if worn

all seals

water pump impeller

clutch if its gettin old

modify the shift star

get the flywheel lightenned

 

Lastly, drill a hole in bottom of the right side of the case connecting the clutch area to the tranny area, about an inch to the rear of the hole that's already there that is blocked by the drainplug. This will improve oil flow to/from the clutch. Yamaha f'd up by putting the drain plug right there.

[suzuki0702]

thanks for the replys guys, i read on some old topics through the search that the shift star is kinda hard to screw with. well im going to replace the crank, probably with wisecos stock or vitos but what all inside am i a going to need to order..i need seals and all that ..anyone know links off hand where to get em? and how do i clean those dirty halves?