Deep Engine Work.

Good. God. I remeber someone telling me about a bolt holding the cases together insdie the filter housing. Unfortunately, on the turbo, it is hidden by the cooler bloack. Removing the block revealed the bolt, and the cases practically fell apart, without touching the bearing retainers for the middle gear.

 

Excellent!!!! I had some trouble finding that one myself. So, how's she look inside?

Greg

 

Well, I must say, it looks pretty good inside for 83,000km. No visible damage anywhere, except the primary chain is a bit slack, and the primary chain guide is cracked. The oil pump chain is loose, but better loose than tight. I cannot believe Yamaha put the starter clutch so far into the engine. The only thing I didn't have to pull was the rods and crank! Unfortunately, the parts I took out looked no worse than the parts I put in, so go figure why the starter was grinding. I have also found out the hard way that you must pull those middle gear bearing retainers. It is nigh impossible to get the cases back together without catching the bearing shims and bending them over. I'm taking Robert's advice and putting some plain countersunk screws back in. I had to take a chisel and hammer to one, since the assembler at the factory swaged the Torx socket so badly I couldn't get the wrench into the head. I have also bit the bullet and ordered a set of rings, since I broke one of the old set, and they were shiny top to bottom. I went to my old shop today and they let me hone the block. It looks really good, no scoring anywhere, but the pistons and head are pretty carboned up from oil blowby from the turbo. I didn't notice any sealant between the two case halves. I was suspecting there would be a gasket there. I put a thin layer of gasket maker on the top case, so it should be good to go when I put them back together. This is the toughest repair I have ever done, made more so by having no place to work. I broke down and bought a sturdy wooden tv stand from the Salvation Army as a workstand, and it helps immensely, but I was sweating bigtime today, with the temperature at 29C and the humidex near 40C.

I think I'll buy a much newer bike next time, lol.

 

Don't you dare! These are the experiences that separate the men from the boys! Doesn't sound like you came off too badly, glad the innards were clean and sound. Bummer about the ring but just as well, you've got a bunch more miles to get out of her now. Wise smearing a bit of sealant on the cylinder block, guarantees no leaks! Carbon is a pain to remove, be wary of nicking the soft aluminum, it will create a high point and a chance for predetonation to occur. Hammer and chisel? Ouch, I would have drilled the head off and used a pair of vise-grips after you had split the case. Hope all the banging around didn't harm the case. Handy as you are, I'd have figured you would have whiped up a 2X4 table from scraps in no time. Weather sounds brutal, keep hydrated (a beer every other bottle of water is ok, alright it isn't but it sounds better than nothing at all).

 

It's worth the price of admission for getting-out those stubborn TORX fasteners. The Craftsman -- Hand-held Impact Tool. Comes WITH some standard bits for removing Phillips and Cross-head fasteners. Accepts BOTH 3/8th and 1/2-inch drive sockets. The set of TORX bits -- including the Seat-belt "Torx" head bit is seperate. The whole deal is under 40-bucks ... but -- 'In my opinion' -- worth every penny. The Impact tool will loosen the most stubborn nuts and fasteners. Makes getting those Torx and "stuck" fasteners out ... a breeze. Perfect for float bowl drain screws.

 

Mac, after searching around, I found this:

Turbo Gasket Set

I know you've already purchased the NA Seca gasket kit and might no longer be looking for the correct gasket kit. I also don't know what this kit includes and it is very expensive. Thought you might be interested though.

I'm going to contact these people and fidn out the details. If it does include everything, including the head gasket, I might completely rebuild my motor.

Greg

 

I have the Athena set. I'm sure it's the same one. It was about $70 less from Parts N More.

 

I sent BikeBarn an email asking for clarification. They offer both a standard Seca 650 kit as well as a kit for the Turbo. If it is in fact Turbo specific, I think I will buy it even though it is terribly over priced.

Greg

 

Couldn't agree with you more. Anyone who ownes bikes or cars should get one. Excellent investment but I paid $12 for my impact with the same specs from WalMart. Harbor Freight sells a cheaper knock-off as well. Just in case a few of our brothers and sisters are needing something in the lower price range.

 

Sounds good. I'll be reusing my head gasket as it is in perfect shape. Got my rings today. The end is in sight.

 

No Harbor Freights around here (is it similar to Fleet Farm I wonder)...plenty of Wal-Marts (sadly).

I'll wait a couple weeks and pick up the Craftsman from Sears.