Had time today to get the head off and see the carnage.
(https://i.postimg.cc/xd58Lhpg/20240629-180048.jpg) (https://postimg.cc/zLLqrtrR)
Head is undamaged except for less than optimal threads in the LH sparkplug hole.
It will get timeserts.
(https://i.postimg.cc/C1JvThPD/20240629-180038.jpg) (https://postimg.cc/7GG1SkyY)
I smacked the piston with my trusty ball-peen. No joy. Stuck tight. Alternate methods will be used.
I think Neil Armstrong walked on that piston. :eek:
Wow! Sure got hot and expanded. And.. Piston crown does resemble the lunar surface. :eek:
Yep it's toasty :bacon: :bacon:
Quote from: m in sc on June 30, 2024, 11:40:58 AMI think Neil Armstrong walked on that piston. :eek:
:patriot:
(https://i.postimg.cc/c4GnyzQ0/20240712-195548.jpg) (https://postimg.cc/4nwdpBLS)
A bit of gentle persuasion with a big truck lug wrench and a couple of licks with a good sized hammer and the piston moved.
(https://i.postimg.cc/9FBr3QmY/20240712-195644.jpg) (https://postimg.cc/6yy9nwG8)
So far damage to the bore appears minimal. Some scoring but nothing I can catch a fingernail on or aluminum on the bore If time permits tomorrow I hope to continue to prep the cylinders for removal.
(https://i.postimg.cc/59Btv2CW/20240712-203012.jpg) (https://postimg.cc/z3f5Y57x)
Took some PB Blaster and a rag to the RH piston so I could see what size it is.
.25
(https://i.postimg.cc/kGfYYDyN/20240719-175843.jpg) (https://postimg.cc/rRR9KV3z)
Had a couple hours of shop time today so I did my 1st time ever top end removal on an RZ. Investigation determined the seizure is actually a nearly locked big end rod bearing on the left cylinder. It was a challenge to get it apart.
(https://i.postimg.cc/xCjKx5p7/20240719-175906.jpg) (https://postimg.cc/063MrYsd)
Minimal if any damage to the bore. Some slight ridges on the exhaust port side but nothing you can catch a fingernail on. If time permits tomorrow I will continue disassembly.
well since the crank was going to be replaced anyway, this is good. got lucky the rod didn't go way off enter on the bearing and punch a hole in the case.
Very lucky indeed. On we go. I hope to do some more tear-down this afternoon.
Could have been a lot worse!
(https://i.postimg.cc/3RxnfKzh/20240720-154405.jpg) (https://postimg.cc/Ffwy7Q9C)
The LH crank seal.
(https://i.postimg.cc/gJt4fCPZ/20240720-154414.jpg) (https://postimg.cc/9RTG9N0m)
(https://i.postimg.cc/T3vQMjBC/20240720-163434.jpg) (https://postimg.cc/zVpTThzg)
Thank God for the sprocket tooI bought from Rick Brett 20 years ago. Sprocket, hardware and the spacer behind it bagged and tagged.
(https://i.postimg.cc/dQTSb0LQ/20240720-172443.jpg) (https://postimg.cc/WtTnrTGx)
Left side stripped. The rotor was uncooperative at first but the 1/2 inch drive impact on the puller convinced it.
Quote from: Kawtriplefreak on July 20, 2024, 06:42:09 PM(https://i.postimg.cc/T3vQMjBC/20240720-163434.jpg) (https://postimg.cc/zVpTThzg)
Thank God for the sprocket tooI bought from Rick Brett 20 years ago. Sprocket, hardware and the spacer behind it bagged and tagged.
I usually try to loosen the sprocket nut with either very long combination wrench or impact while chain still attached on the bike. Unfortunately, I don't always remember and a tool like that would indeed come in handy :devil:
Today's progress in no particular order as I am at the mercy of the image program...
(https://i.postimg.cc/9DXXfjLq/20240824-133329.jpg) (https://postimg.cc/9DXXfjLq)
(https://i.postimg.cc/ZCSK1N3H/20240824-135315.jpg) (https://postimg.cc/ZCSK1N3H)
(https://i.postimg.cc/87ypJnYX/20240824-135541.jpg) (https://postimg.cc/87ypJnYX)
(https://i.postimg.cc/7b7Zs9Cb/20240824-140313.jpg) (https://postimg.cc/7b7Zs9Cb)
(https://i.postimg.cc/624pNLYj/20240824-152637.jpg) (https://postimg.cc/624pNLYj)
(https://i.postimg.cc/V0jsJsyX/20240824-164621.jpg) (https://postimg.cc/V0jsJsyX)
(https://i.postimg.cc/HJVpQ9DY/20240824-165630.jpg) (https://postimg.cc/HJVpQ9DY)
Please note the odd brass sleeve over the shift shaft in the 5th photo from the top. I have no idea why it is there unless it it in addition to or in lieu of the C-clip retainer that I am not certain is installed as I haven't gotten there yet. I plugged the counter shaft hole with a socket to keep dirt out of the case during the initial heavy cleaning of the cases in the parts washer. Left the cases in the parts washer over night with all the little webs filled up for a final soak. All that's left now is to get all the case bolts and nuts out and off and split the cases. Everything is bagged and tagged and all the spacers and bushings and washers are zip tied in the order they came off.
I also did a little frame and swingarm scrubbing with a nylon brush and WD40.
(https://i.postimg.cc/wTXG9k6Q/20240824-164633.jpg) (https://postimg.cc/9rfppZwD)
What is the little L-shaped bracket oriented left to right in the middle of the bottom case? I assume it is something to do with some long gone catalytic converter mounting?
Power valves removed and scrubbed.
(https://i.postimg.cc/fbmFHsyS/20240907-152151.jpg) (https://postimg.cc/zLD0B9nq)
Apparently at some point the retainer for the RH power valve broke and departed the aircraft uncommanded. Note the difference between it and the intact LH retainer.
(https://i.postimg.cc/cHWz2zt9/20240907-152722.jpg) (https://postimg.cc/SXZVzDrC)
And I will be ordering bushing kits as well. The RH has considerable slop and is visibly oblong. The LH much less. I would guess the broken retainer is the culprit.
(https://i.postimg.cc/SNngT4tQ/20240907-162117.jpg) (https://postimg.cc/D8KQ09TR)
LH cylinder scrubbed and plugged.
(https://i.postimg.cc/zBWhMJRW/20240907-162313.jpg) (https://postimg.cc/8Jpsfg4P)
15 minutes in the glass bead blaster
(https://i.postimg.cc/yd5fhYCZ/20240907-164539.jpg) (https://postimg.cc/CBGHS01h)
Another view
(https://i.postimg.cc/NFq6fywp/20240907-164554.jpg) (https://postimg.cc/vghg0ZTV)
Another view
(https://i.postimg.cc/nr2XbMVs/20240907-173306.jpg) (https://postimg.cc/vx1Y5YVM)
Done!
(https://i.postimg.cc/nr2XbMVs/20240907-173306.jpg) (https://postimg.cc/vx1Y5YVM)
RH before
(https://i.postimg.cc/VkBVy8nx/20240907-171619.jpg) (https://postimg.cc/DS0gsRC6)
And after
(https://i.postimg.cc/vBW1h3pt/20240907-173301.jpg) (https://postimg.cc/dkVttmQh)
Another view
(https://i.postimg.cc/nr2XbMVs/20240907-173306.jpg) (https://postimg.cc/vx1Y5YVM)
Ready to pack for shipment to SC for boring
(https://i.postimg.cc/1zS16BrQ/20240907-173541.jpg) (https://postimg.cc/0zV41p4W)
all clean and ready to rock. :olaf:
https://yambits.co.uk/rz350l-gasket-set-full-p-13435.html
What are the 4 little o-rings for in this gasket set?
I figured it out with help. Generic power valve o-rings.
(https://i.postimg.cc/90qJ5QcR/20240921-163047.jpg) (https://postimg.cc/dZw8Gvkw)
My 1st time ever splitting the cases on a Yamaha twin. It came apart pretty easy. The LH crank big end rod bearing is seized and the main bearing just inboard of the LH rod is crunchy on rotation. Noting came apart though. I don't think the cases had ever been apart before.
(https://i.postimg.cc/G2PSHpZW/20240921-172442.jpg) (https://postimg.cc/DJZcN7f6)
I got a 2x4 and numbered it to match the upper case bolts that are numbered on the case as they are all different lengths.I drilled some holes and threaded them in. The service manual says the case nuts and bolts are to be tightened in sequence on reassembly.
timmy finally got his cherry popped. late bloomer. :haw:
:patriot: :patriot:
Just placed an order with Yambits for all the hard parts for the refurb. Power valve bushing kit, transmission bearings, etc... The plan is to get the top case and head bead blasted this week and get the cylinders and head boxed up and sent to SC for the machine work and timecerts in the plug holes. My new Vitos crank and seals kit arrived yesterday.
The fun part is coming
Im going to bury my boring guy this month with stuff. lol. :whistle: :dawg:
(https://i.postimg.cc/YCtdLTCY/20241005-122548.jpg) (https://postimg.cc/nCw46R7h)
New Vitos crank and seals.
(https://i.postimg.cc/15QHbb62/20241005-122456.jpg) (https://postimg.cc/K40BMq0D)
Also got my goody box from Yambits. Haven't had time to open it.
Quote from: Kawtriplefreak on October 16, 2024, 08:13:59 PMNew Vitos crank and seals.
Also got my goody box from Yambits. Haven't had time to open it.
:celebrate: :bacon:
One step closer...
(https://i.postimg.cc/zXrnxr3B/20241022-122632.jpg) (https://postimg.cc/DmxJzRrk)
(https://i.postimg.cc/wjKcjQ0f/20241026-162101.jpg) (https://postimg.cc/fJK0Hm4m)
Top case ready to bead blast.
(https://i.postimg.cc/4NcVqhsz/20241026-175057.jpg) (https://postimg.cc/D82Sb0WZ)
Bead blast complete. Blew all the residual beads off. Ready for an acetone wipe down and a good bake in the shop oven 200 degrees for 20 minutes and a fresh coat of Duplicolor caliper semi-gloss black.
(https://i.postimg.cc/d1wDbWd1/20241112-123734.jpg) (https://postimg.cc/NyCgTkdq)
Top case painted with:
(https://i.postimg.cc/02br1K6p/20241112-124345.jpg) (https://postimg.cc/HV1TQx9x)
Baked in my very short lived shop oven at 200 degrees for 20 minutes at 200. Acetone and tack cloth wipes before and after. Can says 7 days for complete cure. It is a bit shinier than I anticipated. But it is done. Cylinders, power valves, new bushings, seals and o-rings, and a can of caliper paint for the cylinders boxed up and ready to ship to SC.
I have also decided rather than having the plug holes repaired on my original head that I will be buying a new billet o-ring head from Wicked ATV. No more head gaskets.
https://www.wickedatv.com/product-page/rz-350-billet-head
My Bridal Unit is buying the black anodized version for me for Christmas.
(https://i.postimg.cc/9fcGQp6R/20241116-173907.jpg) (https://postimg.cc/ZWD9frK4)
Upper case done.
I also spoke at length with Roger the owner regarding the upcoming 385 build on the Gray Ghost RZ. He will be doing the porting and machine work on the build. I also bought a billet power valve coupler on his recommendation and 2 spare sets of head o-rings.
That seems like a very fair price for the Wicked head. I would have expected nearly twice that. Better deal than air-cooled tops and looks pretty amazing.
IR8D8R
I am looking forward to getting it.
Next on the list:
https://www.ebay.com/itm/226418631431
I bought 2 of the lexan covers.
(https://i.postimg.cc/HxJmsBb1/20241120-122504.jpg) (https://postimg.cc/5YMTs5Ps)
One of my spare clutch covers courtesy of M in SC. Thanks Mark!
I did a quick measurement this morning and will be heading to Harbor Freight this break to get a metal friendly hole saw kit. 3 inches will get me close and a good burr on my Dremel will do the rest followed by a drum sander. Yamaha could have done a better job in the design. Draining water and transmission oil and pulling the side cover to adjust the clutch is just wrong. I also procured a second spare clutch cover for the Gray Ghost RZ just in case.
:clap: Impressive work! :clap:
I'm gonna closely watch this thread. I should have gone similar route :umm:
Thank you! :patriot:
(https://i.postimg.cc/dtwGcf9N/20241123-163944.jpg) (https://postimg.cc/0rXzpcF7)
3.25 inch hole saw aligned and clamped center marked with a sharpie and pilot hole drilled to contact. Clamped down in 3 places.
(https://i.postimg.cc/x17k8pK2/20241123-175255.jpg) (https://postimg.cc/Yv62y3nn)
Lexan window fits perfectly. The initial cut took about 5 minutes. Per M in SC the cutting area was soaked liberally with WD40 and light steady pressure. The Harbor Freight arbor and holesaw by Warrior did a fine job. Then I got out my die grinder and a coarse stone to open the hole up a little more and got rid of the holesaw marks. Next up will be the Dremel and drum sander to finish it up.
(https://i.postimg.cc/CLWBgHZn/20241223-235326.jpg) (https://postimg.cc/BXBQ5FBJ)
Merry Christmas to me! Just got my Wicked Motorsports ATV billet head plus 2 sets of o-rings and billet powervalve coupler, a present from the Bridal Unit.
That new head requires 93 octane/10% ethanol?
...and, is the billet powervalve coupler for insurance - or was yours getting loose?
Would be nice to get a review on improvements you feel from the Wicked head.
They way to a man's heart might not be his stomach. It might be through his toys, instead.
Sweet! :metal: :metal: :metal:
I asked him to set it up for pump gas. I run 90 non-ethanol for the most part. 93 with 10% ethanol if I have to fill up when out and about. If memory serves he said the premium in CA where he us 91 with 10% ethanol. So it should be fine. Roger is a good salesman. And my powervalve coupler was worn. I will be getting another head and associated stuff for the Gray Ghost build as well this coming year. Normal life obligations and stressors have stopped progress at the moment.
(https://i.postimg.cc/T13JGWz5/20250111-173124.jpg) (https://postimg.cc/62FvfT5B)
Finally done. Bought a good set of carbide burrs and got after it. Dressed it with a half round file then bead blasted it again. Ready for acetone wipe and a good bake in my $25 FB Marketplace shop stove.