92 rebuild

[adam89]

i bought this bike from a friend and its condition was in really good condition!



i even got to ride it for about 3,000miles

but then i soon developed a major leak on the left side of the motor so i ordered the both left and right side gasket plus the oil pan gasket for shits and giggles! i had noticed there was a noise previous to this somewhere in the motor but it didnt seem too bad but when i took the left side cover off i noticed this...

next i ordered the cranshaft balancer bearings and proceeded to tear down the motor









and after replacing the balacner bearing i was closing the case back up and on the front left side i torqued the bolt to speqs, the bottom half of the case cracked...so the oil leak i had originally thought was the gasket was actually a hairline crack in the case where the balancer was killing itself due to excessive vibrations from not having a bearing...

so now i actually snagged a whole empty bottom case for 60$ shipped on ebay!!! score
while waiting on parts through this whole process i had been cleaning different parts and repainting the frame






the case had come in fairly quick

at this point ive transplanted the internals into the new case and sealed it back together...ill be putting the top end back on in the next few day and hopefully have the bike running again shortly after i figure out what to do with the broken key that snapped off in the seat lock...any suggestions??? lock smith for new key? can i even get the old gas cap off if i order a new one?

[adam89]

ok so as i was putting the jugs back on over the pistons and while doing this one of the compression rings snapped so i will be ordering another...can anyone point me in the right direction? cheapest place? size? part number? anything will help!

[cheetahman]

Perhaps you know this already, but you really can't just buy a compression ring and stick it in there.  Well......technically you can, but it won't work.  You need to buy 2 complete sets of rings, lightly hone the cylinders, clean thoroughly, check the end gaps, adjust if neccessary, and reassemble according to clymer or haynes.  That's why you can't buy rings seperately.  Also make sure you flush out all oil passages because tiny metal chips are contaminating every internal part and are lodged in every oil passage.  Also every bearing surface in the engine is now suspect and will probably wear out prematurely.  This engine is pretty much done, sorry to say.  Also the oil pump is most likely damaged, even if you can't see it with your eyes.  Plus, you probably havent corrected the original problem yet which was lack of lubrication to that balancer bearing.  Some of these engines appear to have this weakness and they usually fail quite young in their expected life.  It seems like if they last 15000KM, they will go for 100,000KM.  Sorry to say this but I just don't like to see new people throw away money.

[adidasguy]

Junior's problem was crankshaft balance, too. It must have been going out for a long time...




I had spare engine parts so we built a new engine.
Do balancers go out very often?

[adam89]

the compression ring didnt shatter during operation...i was putting the jugs over the pistons when putting the top end back together and i forced the ring into the jugs causing it to become tweaked and when i forced it, it broke...so its not like it happened at 6,000rpms and went all over the motor...during my tare down i blew out all of the oil ports and cleaned the motor of all debri! all bearings in the case were also replaced as well as a new bottom end case...ive ordered the complete set for the pistons and will hone the cylinders...but thanks for lookin out!

[adidasguy]

KEY: Take the seat lock and what's left of the key. A locksmith can make a new key from the 2 pieces.
Then have a spare key made

[cheetahman]

Yeah, I wasn't refering to the most engine damage being caused by the piston ring breakage.  That's minor.  It's how you fix it that's important. 

I am more concerned about the balancer shaft bearing sending microscopic metal shavings into the oil stream and thus, all over the whole engine.  Good for you if you have tried to clean all surfaces, passage ways and ports, and bought new bearings.  Some die hards will say it is impossible to clean all the nooks and crannies well enough, because absolutely everything the oil has touched is contaminated by microscopic particles of metal.  But hey, you can't know if you don't try.  Check the oil pump really well.  Also try and determine why the oil flow to the balancer shaft failed.  Lastly, change the break in oil several times to let stray metal particles out.  Good luck!!!!