331cc install: good news and bad news
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331cc install: good news and bad news
Good news first:
My parts arrived late today and I put it all mostly back together. It went just like last time preparing all the mating surfaces with gasket remover and contact cleaner to make sure they are all mirror clean and dry. Then prepping the new cylinder with a thorough cleaning and then a light wipe of 10W40 on the cylinder wall. Prep the piston by installing the rings, then attaching the piston to the rod, using my home made ring compressor and then installing the cylinder. Then installed the engine head and torqued that down by the required amount.
Then the fun (not) started and that leads to the bad news.
Bad news: somehow the cam chain came off the lower gear, you know, the one down in the engine that is impossible to reach. I learned this as I was re-timing the cams. I had them timed about right and then decided to do one full rotation through a crank cycle when I noticed that the chain appeard to be slipping in a few places. I was like WTF? It shouldn't be doing that. Then it stopped turning the cams altogether. [:@] [sm=boosign.gif] I honestly don't know how it happened but I obviously did something wrong along the way.
Anyway, I called the shop to ask for advice and they said I can put it back on by removing the right side engine cover and that gives access to it. Whew - at least I don't have to undo the cylinder install so all that stays put. So I looked at the right side cover and the shop manual and that covers the clutch and water pump and all that. If it was just the cover to come off, then I'd try it, but looking at the exploded engine diagrams in the manual, that clutch looks like a b*tch with a zillion parts. Also, I think there's a gasket that needs to be replaced if you take off the right side and I don't have one of those. So I asked the shop if they could work me in to reinstall the cam chain and re-time it while they were in there and they said sure, bring it on down. So that's what I did - I left the chain hang and just installed the cam shafts and covers all finger tight, called my buddy w/a pickup truck and he was kind enough to give me an unplanned haul. Hopefully I can pick it up tomorrow if they have one of those gaskets in stock, if not, it will take a few more days. *sigh* I told them if they had it for me tomorrow, I would buy lunch for the whole shop.
Once I get it back, I can finish up the job but there's not much left to do, just reinstall the gas tank, carburetor, and refill the fluids.
So close ... yet so far away. [&:]
My parts arrived late today and I put it all mostly back together. It went just like last time preparing all the mating surfaces with gasket remover and contact cleaner to make sure they are all mirror clean and dry. Then prepping the new cylinder with a thorough cleaning and then a light wipe of 10W40 on the cylinder wall. Prep the piston by installing the rings, then attaching the piston to the rod, using my home made ring compressor and then installing the cylinder. Then installed the engine head and torqued that down by the required amount.
Then the fun (not) started and that leads to the bad news.
Bad news: somehow the cam chain came off the lower gear, you know, the one down in the engine that is impossible to reach. I learned this as I was re-timing the cams. I had them timed about right and then decided to do one full rotation through a crank cycle when I noticed that the chain appeard to be slipping in a few places. I was like WTF? It shouldn't be doing that. Then it stopped turning the cams altogether. [:@] [sm=boosign.gif] I honestly don't know how it happened but I obviously did something wrong along the way.
Anyway, I called the shop to ask for advice and they said I can put it back on by removing the right side engine cover and that gives access to it. Whew - at least I don't have to undo the cylinder install so all that stays put. So I looked at the right side cover and the shop manual and that covers the clutch and water pump and all that. If it was just the cover to come off, then I'd try it, but looking at the exploded engine diagrams in the manual, that clutch looks like a b*tch with a zillion parts. Also, I think there's a gasket that needs to be replaced if you take off the right side and I don't have one of those. So I asked the shop if they could work me in to reinstall the cam chain and re-time it while they were in there and they said sure, bring it on down. So that's what I did - I left the chain hang and just installed the cam shafts and covers all finger tight, called my buddy w/a pickup truck and he was kind enough to give me an unplanned haul. Hopefully I can pick it up tomorrow if they have one of those gaskets in stock, if not, it will take a few more days. *sigh* I told them if they had it for me tomorrow, I would buy lunch for the whole shop.
Once I get it back, I can finish up the job but there's not much left to do, just reinstall the gas tank, carburetor, and refill the fluids.
So close ... yet so far away. [&:]
Da dirty moderator
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Joined: May 2006
Posts: 12,584
From: Pittsburgh, PA
RE: 331cc install: good news and bad news
That sucks about the timing chain... anxious to her the results of the big bore *****...lol..... hope ya get it back soon! good luck man.
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Joined: Sep 2006
Posts: 208
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RE: 331cc install: good news and bad news
Brian don't worry your not the only one to drop the chain, it will be allright. I have no finger nails waiting for your writeup... Are you going with the cvk first and if so did you sort out the jetting.
Thanks man
Francis
Sanford, FL
I want a big bore!!
Thanks man
Francis
Sanford, FL
I want a big bore!!
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Joined: Jul 2006
Posts: 339
From: Abedeen,Maryland
RE: 331cc install: good news and bad news
I think you will find that once you get that new carb tuned in it will be the biggest gain you have seen so far That will really wake up that bike
That will really wake up that bike
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Posts: 881
From: White Rock, BC
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RE: 331cc install: good news and bad news
Oh, no! Brian, I'm shocked that you're actually resorting to work done by the stealership!
This just isn't like you.
Is it really that hard to get the right cover off? The whole clutch assembly comes off too? Uuugh!
This just isn't like you.
Is it really that hard to get the right cover off? The whole clutch assembly comes off too? Uuugh!
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RE: 331cc install: good news and bad news
ORIGINAL: jellyfish
Brian don't worry your not the only one to drop the chain, it will be allright. I have no finger nails waiting for your writeup... Are you going with the cvk first and if so did you sort out the jetting.
Brian don't worry your not the only one to drop the chain, it will be allright. I have no finger nails waiting for your writeup... Are you going with the cvk first and if so did you sort out the jetting.
It's really a toss up for me on this - I so much want this bike back together and ride and then I don't want to have to take it apart again to swap carbs, I just want to ride ride ride. So I really want to install the FCR. But ... I probably will install the CVK since I know there are folks here who are considering the 331cc but would rather not the expense of the new carb if the 331cc is acceptable. While I think I know what the 331cc will do based on my experience with the 300cc, I've been surprised before so unless I change my mind at the last minute, I'll install the CVK at least to break in the new cylinder. Once I get it broke in a little, I'll try a few no clutch wheely tests to get a feel for the effects of the larger displacement.
I did rejet the CVK to deliver more fuel - I hope it's OK: #35 pilot, #130 main, N1TC needle clip on 3rd ring, fuel screw 2.0 turns out. Hopefully if I have to make any adjustments it will just be the fuel screw.
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Posts: 966
From: Ottawa, Ontario
RE: 331cc install: good news and bad news
Try not to loose too much sleep tonight in anticipation. Now you probably understand what the NASA astronauts feel like a day before the launch!
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RE: 331cc install: good news and bad news
ORIGINAL: Kawi Wawi
Oh, no! Brian, I'm shocked that you're actually resorting to work done by the stealership!
This just isn't like you.
Oh, no! Brian, I'm shocked that you're actually resorting to work done by the stealership!
This just isn't like you.
Is it really that hard to get the right cover off? The whole clutch assembly comes off too? Uuugh!
But hey - I did install the big bore kit.
I just had a sour timing chain moment in the final stages. [&:] I guess that's why I'm not a real mechanic and I should stick with my day job, huh ? [sm=guilty.gif]Hey, come to think of it, it was about this time last time when I did my 300cc install that I poked a hole in my radiator and it cost me an extra day repairing that. Hmmm. Maybe I'm just cursed. Deej, did you do that??? Take your hex off me man! Enough is enough!
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RE: 331cc install: good news and bad news
ORIGINAL: Nobrakes
Good news first:
My parts arrived late today and I put it all mostly back together. It went just like last time preparing all the mating surfaces with gasket remover and contact cleaner to make sure they are all mirror clean and dry. Then prepping the new cylinder with a thorough cleaning and then a light wipe of 10W40 on the cylinder wall. Prep the piston by installing the rings, then attaching the piston to the rod, using my home made ring compressor and then installing the cylinder. Then installed the engine head and torqued that down by the required amount.
Then the fun (not) started and that leads to the bad news.
Bad news: somehow the cam chain came off the lower gear, you know, the one down in the engine that is impossible to reach. I learned this as I was re-timing the cams. I had them timed about right and then decided to do one full rotation through a crank cycle when I noticed that the chain appeard to be slipping in a few places. I was like WTF? It shouldn't be doing that. Then it stopped turning the cams altogether. [:@] [sm=boosign.gif] I honestly don't know how it happened but I obviously did something wrong along the way.
Anyway, I called the shop to ask for advice and they said I can put it back on by removing the right side engine cover and that gives access to it. Whew - at least I don't have to undo the cylinder install so all that stays put. So I looked at the right side cover and the shop manual and that covers the clutch and water pump and all that. If it was just the cover to come off, then I'd try it, but looking at the exploded engine diagrams in the manual, that clutch looks like a b*tch with a zillion parts. Also, I think there's a gasket that needs to be replaced if you take off the right side and I don't have one of those. So I asked the shop if they could work me in to reinstall the cam chain and re-time it while they were in there and they said sure, bring it on down. So that's what I did - I left the chain hang and just installed the cam shafts and covers all finger tight, called my buddy w/a pickup truck and he was kind enough to give me an unplanned haul. Hopefully I can pick it up tomorrow if they have one of those gaskets in stock, if not, it will take a few more days. *sigh* I told them if they had it for me tomorrow, I would buy lunch for the whole shop.
Once I get it back, I can finish up the job but there's not much left to do, just reinstall the gas tank, carburetor, and refill the fluids.
So close ... yet so far away. [&:]
Good news first:
My parts arrived late today and I put it all mostly back together. It went just like last time preparing all the mating surfaces with gasket remover and contact cleaner to make sure they are all mirror clean and dry. Then prepping the new cylinder with a thorough cleaning and then a light wipe of 10W40 on the cylinder wall. Prep the piston by installing the rings, then attaching the piston to the rod, using my home made ring compressor and then installing the cylinder. Then installed the engine head and torqued that down by the required amount.
Then the fun (not) started and that leads to the bad news.
Bad news: somehow the cam chain came off the lower gear, you know, the one down in the engine that is impossible to reach. I learned this as I was re-timing the cams. I had them timed about right and then decided to do one full rotation through a crank cycle when I noticed that the chain appeard to be slipping in a few places. I was like WTF? It shouldn't be doing that. Then it stopped turning the cams altogether. [:@] [sm=boosign.gif] I honestly don't know how it happened but I obviously did something wrong along the way.
Anyway, I called the shop to ask for advice and they said I can put it back on by removing the right side engine cover and that gives access to it. Whew - at least I don't have to undo the cylinder install so all that stays put. So I looked at the right side cover and the shop manual and that covers the clutch and water pump and all that. If it was just the cover to come off, then I'd try it, but looking at the exploded engine diagrams in the manual, that clutch looks like a b*tch with a zillion parts. Also, I think there's a gasket that needs to be replaced if you take off the right side and I don't have one of those. So I asked the shop if they could work me in to reinstall the cam chain and re-time it while they were in there and they said sure, bring it on down. So that's what I did - I left the chain hang and just installed the cam shafts and covers all finger tight, called my buddy w/a pickup truck and he was kind enough to give me an unplanned haul. Hopefully I can pick it up tomorrow if they have one of those gaskets in stock, if not, it will take a few more days. *sigh* I told them if they had it for me tomorrow, I would buy lunch for the whole shop.
Once I get it back, I can finish up the job but there's not much left to do, just reinstall the gas tank, carburetor, and refill the fluids.
So close ... yet so far away. [&:]
I've dropped the odd cam chain and caused myself all manner of extra work.
But I would have backed you to put it right without the dealerships help.
You are clearly well capable of performing any kind of mechanical work on any part of your bike.
You would have found the clutch thing a doddle.
Looking forward to the results.
cheers
Senior Member
Joined: Jan 2006
Posts: 3,483
From:
1st Gear Member
RE: 331cc install: good news and bad news
Hey Brian,
I'm with Neil on this you would have handled it easy, shame you don't have the time. Anyway good luck you know we are ALL waiting till it's back together and running. Can't wait for the report. [8D]
I'm with Neil on this you would have handled it easy, shame you don't have the time. Anyway good luck you know we are ALL waiting till it's back together and running. Can't wait for the report. [8D]