Rebuilding an R1 Engine

[Marcheline]

Managed to acquire a used R1 2001 engine from a fellow forumer and haven't really gotten down to splitting it apart due to my exams. Well, exams are over now! Will update my progress as i get along. Items on agenda:

 

1. Piston Rings

2. Rod Bearings

3. Inspect Gear teeth (particularly the 2nd gear)

4. Install new Clutch Basket and assorted plates

5. Replace Timing Chain

6. Valve Clearance

 

My current R1 engine has a cracked block, releasing fumes from the crankcase which cannot be routed to the airbox. It's burning engine oil at a rough rate of 100ml per 2000km. In layman speak, my bike smokes a lot at stop-lights as the unfiltered smoke is routed to the bottom. I smell of engine oil after every ride.

 

Anyhoo.. welcome to my room, pardon the mess.

my cat is sleeping in that box on the mattress:

http://i47.tinypic.com/am4box.jpg

 

Engine with the cylinder head cover removed.

http://i1006.photobucket.com/albums/af182/wadafark/29gls2o.jpg

 

Double camshafts with the cam covers. One cam controls the intake (total of 12 valves) and the other controls the exhaust (8 valves). It's a 20 valve engine. Headache..

http://i1006.photobucket.com/albums/af182/wadafark/2a0c2zt.jpg

 

Cylinder head removed, with 4 piston heads visible. The black parts are the carbon and unburnt petrol that have to be scraped off. The gap between the combustion chamber and the outer block is the water jacket where the coolant flows during operation.

http://i1006.photobucket.com/albums/af182/wadafark/2qx7znt.png

 

Engine with the visible cylinder head and valve train contained within it.

http://i1006.photobucket.com/albums/af182/wadafark/2n9ls3n.jpg

 

The clutch assembly on the left and the timing chain visible on the right, with the pickup rotor. Part of the con-rod is visible thru the peep-hole. Not sure about the condition of the clutch on this bike yet, but i already purchased a new assembly.

http://i1006.photobucket.com/albums/af182/wadafark/kdn1u9.jpg

 

Currently need to get a flywheel holding tool to hold the clutch basket and prevent it from rotating to remove the other rotary parts of the engine. Will update once there's progress. Stay tuned!

Edited January 5, 2010 by Marcheline

[nuad]

big respect for this monster task! (i think) not much people in singapore, including me , dare to do a DIY heavy duty proj like this , valve work seems to be very precise and tricky...

 

all the best ! ups!

[dragonforce]

to you.. locals rarely do this.. many of us rely on our mech to do it..

[Marcheline]

That's what I thought too. Locals are turned off from such work as 87% of us stay in HDB units, equating to no garages to do such DIY tasks. It then simply becomes a matter of will. The learning value is priceless though.

[JbAtRaCeR]

That's what I thought too. Locals are turned off from such work as 87% of us stay in HDB units, equating to no garages to do such DIY tasks. It then simply becomes a matter of will. The learning value is priceless though.

 

Upz for you bro...I'm also looking forward to rebuild my cbr1100xx engine in a few years time in my room also since i dont have any garage. Kind of like a hobby...slowly rebulit the engine bit by bit.

 

I've rebuild 6 cylinder diesel engines at my workplace...now looking forward into rebuilding motorcycle engines as a hobby. Do have the service manual in hand bro,save lots of time and $$ ...

[gwzc_mk2]

wah bro. how much u bought the engine for?

[starr]

wow. you must have great knowledge in engines and stuffs. all the best for ur big project bro. will definitely be waiting for more updates!

[Marcheline]

wah bro. how much u bought the engine for?

In the hundreds range.

wow. you must have great knowledge in engines and stuffs. all the best for ur big project bro. will definitely be waiting for more updates!

Not that great a knowledge. Just some excerpts here and there from reading. I guess anyone with the want and will would be able to do it, no matter what their background is. Updates are gonna take some time. Just called Hong Leong Singapore and they said that they don't bring in the engine tools for sale.

 

No luck at Auto-Machinery either. Guess it's back to ordering the tools online or checking the hardware shops cluster near the industrial estates.

[dragonforce]

That's what I thought too. Locals are turned off from such work as 87% of us stay in HDB units, equating to no garages to do such DIY tasks. It then simply becomes a matter of will. The learning value is priceless though.

 

yup. to the extend of changing engine oil. if i had another bike or even a car.. i would want to try to do alot of diy stuff.. if cannot do it in a day still can have own transport.. another problem is living in a hdb.. if you forget to bring some tools or equips out.. you got to leave all your stuff you have dismantled in the car park/ void deck.. unless do what you have done, bring the whole assembly to your room.. but its going to mess up my already messy room and pis* my parents off.

[JbAtRaCeR]

In the hundreds range.

 

Not that great a knowledge. Just some excerpts here and there from reading. I guess anyone with the want and will would be able to do it, no matter what their background is. Updates are gonna take some time. Just called Hong Leong Singapore and they said that they don't bring in the engine tools for sale.

 

No luck at Auto-Machinery either. Guess it's back to ordering the tools online or checking the hardware shops cluster near the industrial estates.

 

Bro..maybe you want to try shops at jalan besar. I still prefer getting at Lok Yang(near international road),maybe becoz near my workplace and they stock more stuff.

 

Btw bro some special tools you dont need to buy,juz need some creativity.

[Phang]

Very impressive bro Marcheline

 

bro JbAtRaCeR, I think he needs this

 

http://www.accu-products.com/images/uploads/Yamaha_YM-91042.jpg

[Marcheline]

Yup Phang! That is what I need, but the generator flywheel holding tool would do just fine. I'm contemplating on ordering one from Pitposse as they have stock on the flywheel puller too. It's an M16 x 1.5 Hardened Bolt. But shipment from them to Vpost, then Vpost to here.. That's gonna be 2 weeks.

 

I just came back from Lok Yang, they don't have it. Jalan Besar next. Anyone has any idea where i can find something like this here in Singapore?

 

http://i47.tinypic.com/349b8f7.gif

 

My mistake. Should have ordered the tools in first. I think I'm gonna tie a string to the entire circumference of the flywheel (in and out) and we'll see how it goes. At 50Nm, I think it'll just snap. If only I had a metal welder and some spare materials.. This tool looks simple enough to weld together.

[shiraz]

Looking good! How many KMs were on the engine? BTW, might as well do the cam bearings when you are in there. (Don't know how these engines run anyway!)

 

It's magical how these Japanese guys can make 20 valves work together at such a speed!

 

Germans did that with cars but look at the price difference!

[Phang]

From my experience of buying uncommon tools/parts in Singapore. Unless you know exactly where to get it from, most of the time buying from overseas is more cost/time effective.

 

I am really tired of hopping from shop to shop. If you factor in the time, parking charges, petro and etc that you spent hunting down an uncommon tool/part, international delivery charges seems reasonable

[Marcheline]

Looking good! How many KMs were on the engine? BTW, might as well do the cam bearings when you are in there. (Don't know how these engines run anyway!)

 

It's magical how these Japanese guys can make 20 valves work together at such a speed!

 

Germans did that with cars but look at the price difference!

I'm not really sure. Seller claimed he bought it from the States at 9000 miles. Which is why I'm tearing it up to check and just replace the important pieces while its apart. How's your pink Harley chugging along?

 

From my experience of buying uncommon tools/parts in Singapore. Unless you know exactly where to get it from, most of the time buying from overseas is more cost/time effective.

 

I am really tired of hopping from shop to shop. If you factor in the time, parking charges, petro and etc that you spent hunting down an uncommon tool/part, international delivery charges seems reasonable

Great advice. Think I'll just go ahead and order from Pitposse. Btw, what's with the mid finger on the Zephyr, Phang? Haha. Have you gotten around to tearing into your engine?

[S750WP]

I'm not really sure. Seller claimed he bought it from the States at 9000 miles. Which is why I'm tearing it up to check and just replace the important pieces while its apart. How's your pink Harley chugging along?

 

 

Great advice. Think I'll just go ahead and order from Pitposse. Btw, what's with the mid finger on the Zephyr, Phang? Haha. Have you gotten around to tearing into your engine?

 

I have DIY a flywheel holding tool with 2 straps of metal, idea from haynes manual, I have not used it though, you can borrow it and see if it work.

[MIGHTY MAX]

nice work............

[FB666Y]

For the clutch boss holding tool you might want to try the shops that sell aftermarket slipper clutches. I know Sporting use to sell STM slipper clutches, and they shold have the tool. You could also try Mezzo in Kaki Bukit. Not sure if they will sel it to you but its worth a try - or you could ask to borrow it.

 

From prior experience most shops will not use the tool when dismantling the clutch basket. I burned two sets of clutches on my 04 R1 and on both occasions the tool was not used. If youre friendly with any shops you might ask the mechanic how they manage without the tool.

[JbAtRaCeR]

 

From prior experience most shops will not use the tool when dismantling the clutch basket. I burned two sets of clutches on my 04 R1 and on both occasions the tool was not used. If youre friendly with any shops you might ask the mechanic how they manage without the tool.

 

Yes bro agree...it comes to your creativity...Like on a diesel engine cylinder head. To remove the valve keepers,i simply use a socket and 6 inch extension,knock the extension using a hammer. ViolA`~! keepers pop out.

[Marcheline]

For the clutch boss holding tool you might want to try the shops that sell aftermarket slipper clutches. I know Sporting use to sell STM slipper clutches, and they shold have the tool. You could also try Mezzo in Kaki Bukit. Not sure if they will sel it to you but its worth a try - or you could ask to borrow it.

 

From prior experience most shops will not use the tool when dismantling the clutch basket. I burned two sets of clutches on my 04 R1 and on both occasions the tool was not used. If youre friendly with any shops you might ask the mechanic how they manage without the tool.

From what I heard, an impact wrench would throw it right off. But I don't have access to one, and a reliable electric impact would set me back by at least $300. I've messaged S750WP regarding his flywheel holder, we'll see how it goes. Project's stalled for two days now.. And the semester break's coming to an end!

Yes bro agree...it comes to your creativity...Like on a diesel engine cylinder head. To remove the valve keepers,i simply use a socket and 6 inch extension,knock the extension using a hammer. ViolA`~! keepers pop out.

Idea! I was wondering how to remove that valve cotter and spring from the cylinder head without that "special" tool to push on the circumference of the springs. Now I know.. Thanks bro.

[Phang]

Yes, an impact wrench will undo the fastener without some form of holding/locking tool. But you will need to hold it still if you are using a torque wrench to reinstall it at the later stage. Unless you are planning to put it back using the same impact wrench

 

As for valve cotters, again, you still need a valve spring compressor to put them back

[Terrible One]

Good to have u and guys like Phang and S750WP to keep up motivated.. Cheers

[JbAtRaCeR]

 

As for valve cotters, again, you still need a valve spring compressor to put them back

 

Ouh ya...forget to mention..

[shiraz]

I'm not really sure. Seller claimed he bought it from the States at 9000 miles. Which is why I'm tearing it up to check and just replace the important pieces while its apart. How's your pink Harley chugging along?

 

Pink? Nooo.. It's red!

 

9000 miles is too low! I would scrutinise everything in there! Since it's an R1, it might have been used only on the race track which would explain the low mileage. Otherwise, It's underutilised!

[ronz]

actually 9000 miles is alot right? come to think of it. miles and km