2 months ago
19
Guys & gals, this is simply a crazy, monolithic undertaking I?ve started with zero anterior hands-on experience. I?ll instrumentality you done a implicit rebuild of a trashed 2016 exemplary R15 V2 motorcycle. The writeup volition beryllium long, truly agelong and volition beryllium done successful aggregate parts astatine the least. I anticipation you each bask going done this arsenic overmuch arsenic I'm enjoying doing it and penning astir it!
A small backstory: I utilized to enactment successful Titan Precision Engineering, Hosur wherever I was a squad pb of an assembly division. In my squad was a lad who went from awkward subordinate to bully workfellow to a bully friend. Let?s telephone him Mr. P. Now, Mr. P is simply a passionate idiosyncratic but conscionable a tiny spot na?ve astir the ways of the world. I utilized to thatch him a batch astir some machines and wide topics until I left. He besides near for a antithetic occupation soon aft but ever stayed successful touch.
One good day, I got a telephone from him. ?Sir!? helium exclaimed. ?I?ve bought myself a motorcycle, sir!? helium gushed retired elated and sent maine 2 images.
I was blessed for him for the entirety of 2 seconds earlier my captious caput kicked in.
Me: Oh, wow. Fancy motorcycle indeed. How overmuch did you get it for? How galore kms has it done and what model?
He: It?s a 2016 model, has tally 71500 kms and I got it for 30K.
Me: Wait what? Did you accidental 71500 oregon was it 7150?
He: 71500, sir.
Me: Um, did you cheque everything? Is the motor sounding good? Are the tyres good to do? Is the artillery good?
He: The motorcycle looked bully and I bought it. Have I done thing dumb?
Me: Uh, it?s okay. Tell maine what known issues are there.
He: The motor makes weird noises. I don?t truly cognize overmuch else. And oh, forks are leaking, hehe.
Me: Oh goodness me. Alright instrumentality it to a bully mechanic. 8 years and 70K+ kms means you?re owed for a batch of replacements. Engine oil, coolant, concatenation and sprocket set, beforehand forks, tyres beforehand and rear, Clutch inspection and such. And we besides request to look astatine the sound from the Engine.
He: What connected world and however bash you cognize each this? Alright, ne'er mind. So the happening is, I don?t person a bully mechanic present wherever I live. I?ll bring it to you and let?s see.
And since the motorcycle had been staying idle for a fewer days, helium had to really transport it due to the fact that the motorcycle wouldn?t commencement nary substance what. He brought it to my location and archetypal things first, I checked the artillery and definite capable it was much dormant than the hairsbreadth connected my bald head. I jumped it with my Bullet?s artillery and the happening started up each bully and beauteous until the dreaded gearbox grinding sounds came. I moved it astir for a spot and definite enough, the clutch and crankcase had superior issues.
We called a known mechanic and the words helium said scalded mediocre Mr. P to nary extent.
?Sir, this motorcycle is simply a discarded of time. Please scrap it and bargain thing else,? helium said and walked off. We didn?t suffer anticipation yet and called up the authorized centre. If anything, those guys would ever regenerate parts happily and slap a hefty bill. The feline from the centre looked astatine it, heard the noises and said, ?Sir moving connected this is simply a waste. I?d suggest you propulsion this distant and bargain immoderate different bike.?
Mr. P was astir connected the verge of tears. One tin recognize the symptom a lad from a not truthful well-off household would feel, buying his imagination motorcycle and proceeding it is not worthy repairing even!
This was erstwhile I got a brainsick idea. Since the motorcycle was scrap anyway, I suggested that we springiness it 1 past changeable and unfastened it up ourselves and spot what the harm was. At the precise least, we could usage this arsenic a learning opportunity. Our precise archetypal motor physique acquisition connected a Japanese liquid-cooled engine; radical who cognize maine ever telephone maine brainsick for the close reasons indeed.
The motor was moving good which meant it hadn?t seized up, yet. Mr. P agreed and we acceptable to work. I went consecutive to the manual room tract and downloaded the store work manual and started disconnected with the motor mounting bolts aft taking disconnected the substance tank, the coolant hoses and the throttle body.
Six hours later, each the fairings, the exhaust system, the coolant strategy and the motor were disconnected the motorcycle and the archetypal slap we got was from the lipid drain plug. The happening conscionable folded implicit similar it was made of dough. The hexagonal illustration became a cleanable ellipse successful the archetypal effort and present determination was nary mode to drain the lipid without making a immense mess. Well, it wouldn?t beryllium a trashed motorcycle if everything worked, truthful we decided to worker connected with the crank covers instead.
The crankcase covers were removed and the lipid was drained retired erstwhile we saw thing nary motorbike proprietor oregon mechanic wants to see; the forbidden milkshake. The damned coolant had mixed with the lipid and the full motor was afloat of slimy brown-white sludge! The lipid was burnt arsenic good to apical disconnected our misery. This meant each and each screw, seed and washer had to beryllium taken isolated and cleaned earlier being enactment backmost successful and past the full motor had to beryllium flushed due to the fact that otherwise, the motor would conscionable beryllium a perpetual lipid spoiler.
We called it a time and went to slumber wondering what other was successful store for us.
The adjacent day, we acceptable astir opening the motor itself. First things first, the clutch came off. The plates were a spot worn disconnected truthful we decided to regenerate the full set. The outer lodging and the canine lodging were bully to spell nevertheless truthful it was conscionable the sheet sets that needed replacement. Sat down and cleaned each the muck retired of the parts.
Moving connected to the crankcase, we recovered retired that the motor had antecedently been opened by idiosyncratic incompetent due to the fact that immoderate of the crankcase screws were missing! I opened up the cylinder caput and recovered the camshaft timing pulley successful the incorrect alignment! No wonderment the motor sounded similar cars Jeremy Clarkson typically bought during apical cogwheel specials.
?Gah!? I exclaimed and pulled isolated the cylinder head. The bore was successful cleanable information which gave much alleviation to some of america than we would similar to admit. The piston astir looked arsenic if it had been dropped successful a bucket of tar though. Again, I brushed disconnected the c deposits connected the piston with a toothbrush and immoderate diesel earlier wiping it cleanable with brushed cloth and packing it up neatly arsenic I did not privation the piston grooves to get dented oregon scored portion lying around. Mr. P went location aft this and I sat down to enactment much connected getting everything apart.
Then came the coolant pump disconnected the cylinder head. This is erstwhile things went from atrocious to worse. I knew thing was incorrect determination successful the circulation strategy starring to the coolant-oil mix. Opening the pump gave each the answers.
Removing the seal revealed a batch of residual coolant wherever determination was expected to beryllium none. I took isolated the 2 sides of the pump and inspected the shaft and bearings and definite enough, the coolant bearing was afloat of slimy gunk. On the different broadside of the bearing was thing which was meant to beryllium a seal but was present much of a room strainer owed to each the holes and tears it had. It was royally gone!
There was nary constituent successful wasting clip with the pump. Further, the lodging looked lightly damaged from tools being utilized forcefully connected it antecedently truthful I decided to regenerate the full pump and determination on.
Next successful enactment was the cylinder caput successful itself. The aforesaid gunk and burnt lipid occupation was present arsenic well. I removed the rocker arms and subsequently, the camshaft. Save for immoderate unsmooth machining edges and burr connected the surface, the camshaft was successful truly bully condition. It was astir apt replaced, I couldn?t know.
I?ve had acquisition moving successful a machining and instrumentality portion assembly mill successful my archetypal institution wherever we often assembled precision components similar question usher rails, bearings etc. That acquisition taught maine to ever cheque the bearings doubly earlier deeming them good. I did not person costly measuring gauges of immoderate benignant with maine truthful I did the adjacent champion happening I could. I rotated the camshaft bearing and listened to and felt the bearing races for immoderate signs of debris grinding oregon brinelling effects. In a nutshell, brinelling is what happens erstwhile the balls of a shot bearing excavation into the outer oregon interior races of the bearings starring to noise, vibration and eventually, bearing failure.
Sure enough, the camshaft bearing was not successful bully signifier truthful decided to person that replaced.
With the camshaft out, I had to instrumentality retired the valves held successful spot by beardown springs. What I needed was a valve compressor instrumentality and what I had was a 10-inch vise which I made myself; much connected that later. With the close attachment, it could enactment without shooting the springs disconnected similar bullets. I took a stainless alloy tube and made a valve compression extremity tool, utilized it with the vise and got the valves off. The valve seals were successful bully information but determination was nary constituent successful keeping them due to the fact that the valves were wholly destroyed.
I was reasonably definite that this was NOT expected to beryllium successful the cylinder caput on with the rocker arms!
This meant I was successful for a implicit valve replacement arsenic well. Sigh! Called it a time and stowed distant everything successful my retention container to person a look astatine it aft I instrumentality from a hometown visit.
To beryllium continued. Thanks for sitting done this torture until now!
