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Winter Project Engine Breakdown

4K views 37 replies 14 participants last post by  devildogae 
#1 ·
So looks like I dropped a valve at the track. Good way to ruin a great day on the bike. So now I'm in teardown mode and maybe rebuild. I will for sure need a new cylinder head and piston. Going to crack the block soon, but I did notice some damage to the cylinder bore wall. Is this a lost engine guys?





I wanted to show everyone the damage caused by a dropped valve. Guess the valve and piston can't occupy the same space at the same time.





 
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#4 ·
You are going to need atleast $3.5k in parts if you walk into the dealership and try and order what you need..........

The cylinder is part of the case halves---about $1400

The cylinder head is another-------------about $1700


Then you still would need all the smaller parts-----about $500-$1000 depending,,,,,,

valves, piston, 1 rod and all 8 of the bolts/nuts, guide seals, springs-retaining washers and collets, maybe a camshaft and buckets, all the gaskets and seals and in that deep---oil pump rotors




SET-CRANKCASE
14001-0159
$1,369.85




HEAD-COMP-CYLINDER
11008-0183
$1,674.20


Time to go do some used engine shopping and then refresh that with new bearings etc.....You will still be about $500-$700 in parts on top of whatever the engine costs you to aquire but, it will be fresh!
 
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#6 ·
This is why I just went and found an engine on Ebay. $900 and some garage time swapping motors.... the engine has had over 25k miles put on it since then. And had about 4k on it when I came into possession.
 
#8 ·
I don't think a 2009+ will bolt into an '05 without some modifications.

I might be wrong but I believe the mounting points are much different. Completely new frame design in '09.
 
#10 ·
Yikes...that's no good dude...I'm not expert by any means, but I have to believe you'd be better off buying a used engine and popping that sucker in there :O
 
#14 ·
Cam cover bolts are reusable...........no need to replace those


But most certainly the 8 con rod bolts and nuts!

I do all new gaskets all the time in the shop, but have had to re-use gaskets when at track before with no ill effects........so............
 
#18 ·
hmmmm what makes a valve drop like that???

Sorry to see it man, But do like the guys have said grab another motor off eBay.
Talk to the seller, try to get some kind of warranty, Low mileage, & now is the time of year to do it too.
 
#19 ·
Well its a track only bike, very high rpms and a possible cam chain that's stretching. Also it's possible to have it skip teeth at very abrupt high rmp, like when I dropped it into second trying to shed speed before a hairpin off the straight.
 
#20 ·
I think I just discovered something here gents. Before my breakdown, I was having some problems with the bike. I would get some stalling when on the throttle coming outta corners. I also noticed in a race that other 600 bikes has much more power/acceleration, but I attributed it to use error. Well looking at this image, I might have figured out my problem. Do you think it's possible that I had Either a compression problem or was without a cylinder? The carbon build-up on the damaged cylinder is much less than the others.

 
#21 ·
So I got to spend a little time in the garage this weekend. Very good therapy btw. I noticed some pits on my main journal pins on the crankshaft. So I took a file and took all the high places down. Then I polished and buffed the heck outta those pins and the connecting rod journals as well. Looking and feeling awesome! I also measured them with a micrometer, very please everything is within spec.

 
#22 ·
I then proceeded to clean my pistons. To test, I placed one piston in Acetone and three others in brake clean. I then took a brass wire brush and began to scrub. The one I soaked in Acetone came out looking like this.



The ones I soaked in brake clean came out looking like this:


It's pretty simple to see the Acetone worked great. I did however use a dermal wire wheel to get the hard to get corners. I'm very hopeful they will be as clean as new once they are finished.
 
#26 · (Edited)
Update, almost have my motor together. These are pics just after I put the halves together. Honed cylinder, new piston rings, new big end connecting rod bearings. I didn't replace the crankcase bearings because they were within spec. All new gaskets, Cham chain and lots more not mentioned. My old cam chain was really stretched. I decided to put new clutch friction plates in and new clutch springs. They should be here this weekend. Going to upload more pics when I can.





 
#27 ·
So all in all how deep are you $$$ wise in this project? It's pretty impressive what you've managed to pull off all by yourself!
 
#28 ·
I just did the math. For all the new parts, special tools, crankcase, cylinder head, and anything else I bought, I have spend about 1k in this project. I found a used engine for $900 then have to pay shipping and who knows what condition it's in. I figure I've spend less, have a fresh engine and have learned a ton in the process. There is always a chance I did something wrong, but I have been meticulous and taken my time.
 
#29 ·
Sub for a cool project. I want to rebuild this spare motor I have once I get the time. The only part I'm a little worried about is when it's time to degree it. That's the part that will make or break you and I still doing understand how is done. I hope it's one of those things you get once your physically doing it. I wish you took more pictures though. "Hey guys I'm recording my engine, now look it's together"
 
#30 ·
Here is the bottom of the head I got from a donor bike. I spent a lot of time sanding and polishing the intake and exhaust ports. I also did a valve job grinding the valves into the seats for a better seal.


I had to wait weeks to get in those 8 O-rings to complete the head. After they are installed I rechecked the valve adjustment and all is good to go.


I got the motor installed into the frame with a floor jack. It wasn't to bad to get done by myself. Just a little time and patience is all.



Now she is all back together. I'm going to start her up when I get home just for a second to make sure she starts. I'm going to wait to break her in on the track. I will get a start up video for this thread.
 
#38 · (Edited)
I took everyone's advice and took the bike to be broke in on the dyno. I'm not sure how many runs they did but I got a 10% hp gain from base. I'm sure after the rings totally Finnish seating I will see more. Changed the oil and filter when I got her home. Oil came out glitter chocolate milk.

 
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