Rebuilding an R1 Engine

[zx10]

The teardown is more or less complete. Pistons have been removed.

 

The 4 con-rod end caps removed, revealing the pistons in the cylinder. The caps had to be knocked out softly with a mallet. With that, the crankshaft is removed. The driven gear on the top left was simply lifted out from the assembly. The pistons cannot be simply removed from hereon. They have to come out from the top of the cylinder, not the bottom.

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0115.jpg

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0117.jpg

 

The numerous un-threaded holes you see on all the parts are the oil galleries. That is where the oil flows to lubricate the bearings and other critical components of the engine.

 

With the driven gear removed, the drive gear is visible. The two parts sticking out are the two shift forks.

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0118.jpg

 

The end caps have to be installed in their original positions. Hence, the markings. The journal bearings will be removed and replaced when its time to purchase the parts.

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0124.jpg

 

Overturning the engine again. The styrofoam pieces that you keep seeing in the pictures all came from a toy which was bought for my niece.

 

The cylinder head is then removed to accomodate removal of the pistons.

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0120.jpg

 

And they're out! Somehow, this photo reminds me of the death-pods from War of The Worlds.

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0123.jpg

 

The upper part of the engine, separated from the bottom. All that's left is a T30 Torx socket to remove the drive gears, which I will have to purchase soon. Should cost about $5 at most.

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0121.jpg

 

Basically you can see how the engine works. See the pistons? Those are providing the motive force, transmitted to the crankshaft which rotates and turns the clutch on the top right-hand of the photo. The clutch is connected to the drive gears, which in turn is connected to the driven gears at the top. This then outputs to the front sprocket!

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0114.jpg

 

That's a Cotton-On shirt btw!

 

Next on the list:

Parts purchase and assembly.

 

Hi bro how are you going to tune the timming of the cams?do u need any special tools?

[JbAtRaCeR]

Marcheline:- have you checked the oil clearance of the crankcshaft bearings and con-rod bearings?..How is it?..

[Marcheline]

Hi bro how are you going to tune the timming of the cams?do u need any special tools?

No special tool is required for the cam timing. You just have to line up the pickup rotor and make sure that the two cam-shaft sprockets are in a specific order. It's all listed in the Yamaha manual.

 

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

Marcheline:- have you checked the oil clearance of the crankcshaft bearings and con-rod bearings?..How is it?..

Not yet bro. Manual says to use a piece of Plastigauge for measurement, but I haven't made a trip to the hardware stores yet. Not even sure whether Singapore has it, but its sold for US8.00 for 10 pieces in the States.

 

If I can't find it, I'll just change the bearings for good measure. Might as well replace them while everything's apart.

Edited January 17, 2010 by Marcheline

[JbAtRaCeR]

 

Not yet bro. Manual says to use a piece of Plastigauge for measurement, but I haven't made a trip to the hardware stores yet. Not even sure whether Singapore has it, but its sold for US8.00 for 10 pieces in the States.

 

If I can't find it, I'll just change the bearings for good measure. Might as well replace them while everything's apart.

 

Singapore have it bro...If cannot find juz pm me..

[Marcheline]

Singapore have it bro...If cannot find juz pm me..

Thx bro! But more than likely I'll be changing the bearings.

 

I've compiled a list of parts I need to procure based on a US Microfiche website. Now I need to count the dollars and cents on whether it'd be better to order the parts from the States and ship them here, or order it from Automachinery. (AM told me they don't have quite a few parts and would have to order it in from Japan. Would take 4 - 6 weeks at least)

 

 

Piston Rings 4XV-11603-00-00 (US19.59 x 4)

Piston Pin 4XV-11633-00-00 (US 7.77 x 4)

Piston Pin Circlip 90468-12069-00 (US 1.13 x 8)

Crankshaft Plane Bearings 3GM-11416-XX-00 (US9.61 x 10)

Con-Rod Plane Bearings 3GM-11656-XX-00 (US12.87 x 8)

Shift Shaft Springs 90501-064L1-00 (US 0.28 x 4)

Starter Motor Bolt 95817-06025-00 (US 0.91 x 2)

Timing Chain 94591-49130-00 (US26.82 x 1)

Oil Pump Chain 94580-25078-00 (US 5.78 x 1)

 

 

Cylinder Head Gasket 5PW-11181-00-00 (US33.40 x 1)

Oil Pan Gasket 4XV-13414-00-00 (US 7.05 x 1)

Clutch Cover Gasket 4XV-15461-00-00 (US 4.62 x 1)

Timing Chain Cover Gasket 5JJ-15456-00-00 (US 3.18 x 1)

Generator Cover Gasket 4XV-15451-00-00 (US 3.52 x 1)

 

Still compiling.. Will be removing some items if the list gets too big as some items are not really worn yet and can be re-used again.

[Cpt.ZR]

fwah u are god like man!!

[Phang]

The pistons cannot be simply removed from hereon. They have to come out from the top of the cylinder, not the bottom.

 

Master Marcheline, can you educate me on this? I believe there must be a reason behind.

[Marcheline]

fwah u are god like man!!

Anyone can do this, trust me. Sometimes, it takes a lil realization that the bikeshops factor in high labor fees into the parts that they sell. In any case, it needs to survive, but so do us consumers. Added pluses, you learn more about your bike and the tools stay with you for life.

Master Marcheline, can you educate me on this? I believe there must be a reason behind.

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

 

For the Yamaha engine at least, the cylinder bore does not extend all the way thru the crankcase. The cast protrusions from the lower half of the crankcase block the pistons from coming out from the bottom. Me no master hor.. Hoonda, Kawi and Suzi engines I haven't learnt yet.

 

Edited January 17, 2010 by Marcheline

[Phang]

Understood, compact one piece cylinder block cum upper crankcase casting. I bet the there are not much metal between the cylinder bores.

[JbAtRaCeR]

 

For the Yamaha engine at least, the cylinder bore does not extend all the way thru the crankcase. The cast protrusions from the lower half of the crankcase block the pistons from coming out from the bottom. Me no master hor.. Hoonda, Kawi and Suzi engines I haven't learnt yet.

 

 

For my Honda CBR11xx engine the piston also comes out from the top due to the cast protusion..I think most engines have that..Even the diesel forklift engines have that.

[Marcheline]

Understood, compact one piece cylinder block cum upper crankcase casting. I bet the there are not much metal between the cylinder bores.

You're right. The cylinder bore is a hollow metal casting about 5mm thick, with an aluminium sleeve about 2mm thick (Total 7mm). The inner part which contacts the piston rings are lined with nikasil.

Edited January 17, 2010 by Marcheline

[Phang]

For my Honda CBR11xx engine the piston also comes out from the top due to the cast protusion..I think most engines have that..Even the diesel forklift engines have that.

 

Thanks bro, it feels great when I learnt something new

[Phang]

something like this

 

http://www.camarohomepage.com/ls3/images/656.04a.jpg

[Terrible One]

OT.. Where to get feeler gauge in SG? Wanna DIY valve clreance for my bike and car

[Phang]

OT.. Where to get feeler gauge in SG? Wanna DIY valve clreance for my bike and car

 

Here, I paid $5.00 + GST a few years back

[Terrible One]

Here, I paid $5.00 + GST a few years back

 

Thanks mate!

[antartica]

EXCELLENT STUFF!!!

R.E.S.P.E.C.T. for doing it yourself

 

thanks for sharing Marcheline

[salem77]

if ony i had the time and money to do all dat to my 07

[ronz]

bro u taken the roundness or aligment of ur crankshaft?conrod clearance. i think is steel piston? don't scrap piston will scrap off the coating for high temp. enjoy u can sms if u need anything. i got alot of tools. hee.

[Marcheline]

Hey there, welcome to my room again! Standing space only.

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0126.jpg

 

Parts just came back from a respray with Alan Law. As usual, quality is unmatched. Graphite/Gun-metal!

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0127.jpg

 

And the engine gets pushed to the back of the mess for the mean-time. Busy busy!

http://i1006.photobucket.com/albums/af182/wadafark/DSCF0128-1.jpg

Edited January 21, 2010 by Marcheline

[Terrible One]

I guess I caught the virus too

[gwzc_mk2]

nice work there

[Addictive]

Impressive!

[S750WP]

OT.. Where to get feeler gauge in SG? Wanna DIY valve clreance for my bike and car

 

Bro you back to motorcycle again? Welcome back.

[Terrible One]

Bro you back to motorcycle again? Welcome back.

 

Yeah, bought a Steed a year ago and doing some mods and minor servicing right now. Let's meet up for kopi someday. Cheers!