Right, with my two-day Thunderhill event with Z2 Trackdays done and dusted from the previous weekend (report on that later), I have a couple of plan-free weekends coming up, so I'm really looking forward to getting a lot done on this project. It helps that the days are longer now, but only having time to tackle my list of things to do on weekdays after work means I'm only making incremental ground. But since I can be restless – especially on things I have high interest in – I really can't just sit around and wait for the weekend to come to tick off things in my to-do list for this project. So even though I have a two-year old I need to keep entertained as soon as I get home from work, I make do with the hour or so of daylight I get every weeknight to tinker.
Since I've never torn down any engine at all, a lot of my time at this juncture is spent looking down, and figuring out how things are bolted on, and thus figuring out how I can take them out. Not having some specialty tools that would probably make this task easier is also a bit of a setback, as I have to think about what I could use with the lack of the specialty tools.
Of course, the internet's been helpful, and so has YouTube, such as when I had to figure out how to remove the valve and springs from the head. I saw a YouTube video that showed how to do it with makeshift tools using a deep socket wrench, and a pencil magnet slotted through it – with the pencil magnet resting on top and center of the valve, you push down on the valve spring with the deep socket wrench. The pencil magnet grabs the valve cotter and voila, the whole thing's apart.
Nifty! Only problem was, I didn't have a socket deep enough, with a drive hole large enough for my pencil magnet to fit through. And no, I wasn't about to buy some new tools just to make it work. I just had to think for a minute…until I figured it out!
My “home-made” tools in the background used for the valve removal.
Yeah, that felt good figuring that one out!
But that's just one of many more I have to sort out. Like shouldn't the flywheel just come off when I've undone the bolt holding it in the center? Do I have to cut the cam chain to get it out, since there's an oil passage pipe getting in its way off the case? Do I really need to buy circlip pliers to get those little buggers out?
You know – little things like that.
Eventually, I simply decided to split the crankcase open to remove everything left inside altogether, rather than just one component at a time.
Still not that simple…
Who knew that the piston wouldn't just slide out from below the upper crankcase? Cause I didn’t! Same goes for the transmission, though I did manage to remove half the gears. Actually, I'm going to be leaving the half of the transmission that's still in the case – the mainshaft and the countershaft – otherwise there'd be a big hole on the front sprocket side when the cases are back together, and there would be nothing to mount the kick-start pedal to on the other side.
I just need to figure out how to remove the piston, either from the con rod, or the crankshaft itself.
And in case you're wondering why I'm hung up on gutting the engine; apart from making the bike lighter to wheel around when I have to, I also wanted a completely dry bike to display. Seeing as I intend on putting it inside my house, I didn't want any film or fumes in or out of the bike. Even the forks and rear shock will be drained of oil.