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Old 05-07-2013, 05:25 AM   #7516
mcma111
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Who needs a manual?

http://advrider.com/forums/showthread.php?t=713831

Only difference is head and cylinder torque specs
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87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 05-07-2013, 05:48 AM   #7517
RFVC600R
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Quote:
Originally Posted by mcma111 View Post
Who needs a manual?

http://advrider.com/forums/showthread.php?t=713831

Only difference is head and cylinder torque specs
Like I said, I'll have the lap top in the garage.
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He's the XL600 Jesus, his bike dies for our sins.
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Old 05-07-2013, 07:32 AM   #7518
Carter Pewterschmidt
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Thats why everyone needs more than one bike. While one is down, the others keep you company.
Yes, the other bike being something much newer.
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Old 05-07-2013, 04:44 PM   #7519
davek181
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Yeah, my newer/newest bike is a 97. It's really great to mount modern machinery.
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Old 05-07-2013, 05:12 PM   #7520
Carter Pewterschmidt
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I'm planning on keeping this bike forever as a constant reminder to never get another old bike. Otherwise you ride something new and reliable around, forget about old bike PITAs and you'll end up craigslisting yourself into another nightmare. This way when I get that feeling I can walk into the garage and my 86 will just stare back at me with some section of it dismantled saying NOPE.
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Old 05-07-2013, 06:11 PM   #7521
Reposado1800
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I am putting it together and have one question. Are time timing gears going to line dead nuts on F1 or T1 timing marks. They very close together and I am getting dead nuts on F1. T1 is just a wee bit off.
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Old 05-07-2013, 08:43 PM   #7522
davek181
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Timing is almost never dead on. You have to go with the closest match at T. Good rule to follow is to look at where the marks would be if moved one tooth. If it would be farther off than it is now, you are right.
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Old 05-07-2013, 09:26 PM   #7523
mcma111
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If your looking at the cam timing marks and the rotor marks when the crank is at TDC the cam marks should line up at 9 and 3 'oclock. If not then the cam chain is stretched.
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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 05-08-2013, 04:08 AM   #7524
RFVC600R
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Tear down begins this afternoon! Can't wait to get started! I was upset about this, but now I'm excited to fix it.
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Old 05-08-2013, 06:01 AM   #7525
Homerb
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Well the new sleeve is fitted and bored. Im waiting on the Pro X rod kit to arrive from the US of A, then get it fitted and put it all together, again.
Still no idea where the shrapnel came from that caused all my dramas. Problem ive got now is that the balancer drive gear on the crankshaft has been rotated by about 100, and ive got to try and rotate it back into position, and its a VERY tight press fit.
Im tempted to cut the gear in half to remove it, and get another gear off a knackered crankshaft and press it on in the correct position.
Anyone else had to remove the balancer gear from the crankshaft? How did you get it off without busting it?
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Old 05-08-2013, 06:46 AM   #7526
davek181
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I tried to remove a balancer gear from a spare crank I had. I was going to try to press it apart and replace a bent rod, but soon gave up altogether. i figured it would take more heat and effort than I had to do the job.

What I would be tempted to do in your predicament is forget about pulling the gear off but rather instead leave it where it is and just simply re-mark the gear. It should be easy enough to figure where the mark was in relation to the crank pin and make a new mark to time it to the balancer upon assembly. I don't think there is anything special about the crank gear balance wise. It is just a round gear with a mark timed in relation to the crank mass.

I would check it to be sure that it still runs true with a dial indicator, not that it shifted or tipped a little in it's past trauma.
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Old 05-08-2013, 07:23 AM   #7527
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Here is a shot of the timing marks on a spare crank I have in case you don't have one to compare.

It looks like if you make a mark aligning with the right crank web you will be there pretty close.
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Old 05-08-2013, 08:02 AM   #7528
mcma111
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[QUOTE=davek181;21358710]

I don't think there is anything special about the crank gear balance wise. It is just a round gear with a mark timed in relation to the crank mass.


QUOTE]


If the gear on the crank is out of position/time even if you find another gear tooth that is CLOSE to where it should be the balancer WILL be OUT OF TIME with the crank.
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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 05-08-2013, 08:07 AM   #7529
Reposado1800
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I was looking at the marks seen through the inspection hole at TDC. I went with dead on at F1 because a tooth either way would have been way out.
I got it running. I think I need to replace the pulse generator as it is doing something weird that was happening even before the teardown.
Other than that it runs great.
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Old 05-08-2013, 08:29 AM   #7530
mcma111
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Quote:
Originally Posted by Reposado1800 View Post
I was looking at the marks seen through the inspection hole at TDC. I went with dead on at F1 because a tooth either way would have been way out.
I got it running. I think I need to replace the pulse generator as it is doing something weird that was happening even before the teardown.
Other than that it runs great.

You are supposed to be at T l, not F l. The F mark is for FIRE which is advanced of T for TDC. In other words you may have mis-timed the cam. With the crank at T l this is what the cam timing marks should look like:

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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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