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So I got the front wheel bearings out fairly easy using the method from the manual - pushing the spacer aside and wacking the inner race with a drift. The rear wheel bearings are being difficult. I can't push the spacer enough out of the way to catch enough of the bearing to push it out. I even made a metal punch with an angled tip, but it's not budging. Tried heat on the hub, PB blaster, but no luck. Is there a trick to this?

Also, how do you get the rock hard cush sprocket dampers out? I'm going to have the wheels stripped, blasted and powder coated, and can't have them in there. Should I cooked em out with a propane torch?

Thanks for any thoughts/input.

I have the bottom end of the engine assembled, no side cases. I'd like to put it in the frame and build from there because it's kinda heavy and I'm a one man show. Also, don't want to scratch up my freshly painted side cases. Any reason I shouldn't do it that way?

Anyone looking for an oil pump? I contacted the seller and the pump/side cover is being sold as a unit.

https://www.ebay.com/itm/364148421959?mkevt=1&mkpid=0&emsid=e11021.m5057.l9429&mkcid=7&ch=osgood&euid=2849c358c84f4983845b510660814094&bu=43143656880&ut=RU&exe=0&ext=0&osub=-1%7E1&crd=20230216011544&segname=11021

I'm having a hard time getting the damper rod out of my forks. The rod just spins when I try to loosen the bottom allen bolt. I read in the Haynes manual you can make a tool to shove down there to wedge against one of the flat surfaces to hold it in place. I read elsewhere you can force a broom handle or dowel down in there to hold it in place, and then hit the bolt with an impact driver. Is there a better way that I'm not aware of? Thanks in advance for any input.

My seat latch/helmet lock got gouged up at some point in it's 45+ years. I tried a new key, but no go. So I took it all apart and removed all the pins so any key would work, and it works great. But now I found a little piece of flat metal with a hole on one end that I have no idea where it goes. Not even sure it came out of the lock mechanism (I was also recently working on the generator). Anybody recognize this little piece?

Is a Radian swing arm a worthwhile upgrade from the stock RD400 one?

Got a bunch of free Kawasaki EX650 stuff off of craigslist this am. Front and rear wheels with rotors, complete front and rear brakes, forks with triples. front fender, seat and some clip-ons. Not sure what I'll do with it all. Probably way to beefy for my RD project, but I couldn't pass it up.

https://sfbay.craigslist.org/eby/mpo/d/oakland-kawasaki-ex650-forks-wheels/7524353844.html

I put new outer main bearings on my RD crank, and it rocks just a little bit resting in the bottom case. It's the bearing on the left side (gen side) that doesn't use the 1/2 circlip. I can press down on the outer shaft and make it drop down a bit. If I put the top case on and press down on it, it nearly goes away. I'm thinking (hoping) it will go away entirely when I install the new seals and torque down all the top and bottom case bolts/nuts. Still, it has me concerned. I pressed that left bearing on as far as it could go. There is a slight gap between the bearing and the side of the housing (you can see it in the second pic) - Can you press them on too far?

So I put my shift forks in following the parts catalog (and Dusty's RD400e engine build), and the Factory Service manual. Now that I look closer, the shift forks marked #2 are on the right side (clutch side) and the shift forks marked #1 are on the generator side - on the parts catalog and in Rusty's thread. But the manual has them the reversed. Whats the consensus of those that know all things RD? (The photo's are of my case).
Thanks, JB

Hey everyone, new to the forum - 1st post.
So I spent way too much money on this emotional buy. I know it's a POS. I thought I needed a new project...
I've never really done a total restoration on a motorcycle, let alone a 2 stroke, but here goes. Looking at the bike as a whole is overwhelming, so I thought I'd focus on one thing at a time, shelf it, and move on to the next piece. Right now I'm doing the gas tank. So far I've de-rusted it, taken it down to metal, bondo'd the dents, primed and base coated it. I think I'll take off the chambers next.