Motor tear down has begun!!!!

[Greasey Fingers]

Block was a totally different story. It was pretty much FUSED on there. You cant move it with a few gentle taps with a rubber mallet. The fins on the block are ULTRA brittle, save yourself a headlike like what i got and dont even bother to try and 'knock' it free youll just break fins and be spewing. I dont understand why they didnt design this block to have a few strong areas where you could give it a good whack and it wont break fins.

Dont even try the mallet if its really stuck on. I ended up using a thin paint scraper and gently hammering it into one of the corners of the block to split it and slowy working my way around prying it and breaking the seal. Once i did this it came off easy, it did not seem to cause any damage to the block just made a mess of the old gasket which will be replaced anyway. Its more like slicing it off (guys if this is bad advice please jump in and correct me).

 

[Greasey Fingers]

Ok and now for the equivilent of a bike pulling down its pants and showing the world what its got, heres the pistons and cylinders

 

[Greasey Fingers]

The pistons/rings/cylinders seem to be in ok shape, any thoughts/opinions? The rings all move freely around the pistons and do not have any cracks or breaks in them.

And now the crappy part, heres the broken fins

I still have the peices that broke off and they fit like a jigsaw puzzle. Can they be welded back on?

 

[Greasey Fingers]

And this is where we are up to now, ready to start tearing into the tranny

 

[drewpy]

The pistons/rings/cylinders seem to be in ok shape, any thoughts/opinions? The rings all move freely around the pistons and do not have any cracks or breaks in them.

And now the crappy part, heres the broken fins

I still have the peices that broke off and they fit like a jigsaw puzzle. Can they be welded back on?

whos' been a naughty boy and was whacking the fins to get the barrel off?

or did they just fall off?

weld can be built up using lumi weld, but just dress it and leave them alone.

 

[Pork Chop]

Nice work. Bummer about the fins. I have broken fins on the oil filter cover & I am just going to remove the jaggered edges with a file to make them look less broken.

 

[volcomskater77]

if your really concerned about having a full set of fins, get rid of that rectangle cylinder and get one of the more round ones. looks better imo. lol

and i did a thread on how to split the case, so that might be of some help. tho most of it is common sense haha

 

[Greasey Fingers]

whos' been a naughty boy and was whacking the fins to get the barrel off?

or did they just fall off?

I didnt do it

Yeah thats what my brother said to file them back. So its not worth to try and weld them back? Can they look semi ok after a good file?

 

[Greasey Fingers]

i did a thread on how to split the case, so that might be of some help. tho most of it is common sense haha

I have that saved to my favourites, and have studied extensivly, great thread thanks for posting! Can you get the rounded cyclinder for the 250?

 

[WT100]

I have seen some use JB weld to re-atache fins. Might work if you are planing to paint the head. I'd probably just file that section down.

 

[volcomskater77]

ahhh thats right its a 250. im not sure, im sure someone could chime in

 

[FUBAR]

rememer to clean off that magnet waaayyy down in the bottom by the small take off cover
and i would just go with the jb weld for the fin. wouldnt want to take a chnce on distorting the head by welding on it .

you'll never see it if your clean with the glue

 

[Greasey Fingers]

rememer to clean off that magnet waaayyy down in the bottom by the small take off cover
and i would just go with the jb weld for the fin. wouldnt want to take a chnce on distorting the head by welding on it .

you'll never see it if your clean with the glue

Hi Fubar glad you dropped by and nice thread you made btw, 'crankcase internals': http://www.xs400.com/forum/showthread.php?t=5558

I have read through it quite a few times Ill make sure i clean that magnet your talking about, i dont know where it is now but im sure ill recognise when i see it.

With that jb weld you mix the 2 together then use right? Would it be enough to hold the broken fins if you just layered it across the surfaces of the break and did not build it up over the edges?

 

[drewpy]

this is being over done, its not going to affect the bike at all, they are at the bottom of the barrel so you won't see them.

did any one notice mine when i won best in class at a show? No!

just leave it and spend your thought processes on more meaningful tasks

 

[WT100]

Fair point but as a novice i would do the JBWeld thing just to learn and see if it works. Not like it would take a lot of time and there is always something to wait on.

 

[FUBAR]

you could layer it or just glue the old piece on, the stuffs strong.. but like wise old drewps says you could just leave it and nobodys gona know !

thanks for the kudos on the thread.. it didnt get put in the HOW TOS so i figured it was a waste of time.

 

[Jamin Smitchger]

I am exactly at the point where you are right now. I just took my cyclinder to the shop today to get bored. Really good thread, and yes, a good quality ratchet set can save you so much time and frustration. People who make bad ones should end up in jail.

 

[Greasey Fingers]

did any one notice mine when i won best in class at a show? No!

Well im not interested in 'best in show', i want the award above that. And for that award ALL fins NEED to be intact

nah your right who gives a crap about the lower fins i think ill just file em back, lol.

@Jamin, hey mate hope its going well. Be sure to let us know how your progress is going!

So today i wasnt really in the mood to pull apart the tranny. I was more in the mood for BLING, so i polished an engine cover Its not perfect but i dont care, its gonna go dull after a while anyway. Heres the results, first photo is before and all the others are after. (Btw i found the most important thing for polishing is plenty of BEER to drink)

 

[Greasey Fingers]

Oh yeah and heres my stainless steel engine bolt pack that arrived the other day, thanks yet again ebay. Cant wait to put these bad boys on!

 

[Greasey Fingers]

More polishing, lol...Im gonna wait till my brother comes down before i rip into the gearbox ill feel more comfortable if two of us were working on it. So i took the opportunity and polished another engine cover and cleaned out the little oil window which was totally blacked out before, you couldnt see throught it...its nice and clean now!

Im really enjoying the polishing part, not the actual polishing itself that is hard work and fairly boring. But the feeling of satisfaction is great! To see something old look so much better than what it did look like before.

Anyway heres some pics, same deal its not perfect but good enough for what i want, first one is before others are after.