Thumper Club Forum
Technical => Project Progress => Topic started by: themoudie on August 24, 2016, 11:41:05 PM
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Having removed the petrol tank from Gert (SRX mono, with XT600E motor) that already has a daubed resin repair on the lower left-hand side of the petrol tank! :(
I then drained as much of the contents via the filler and the tank tap orifice, yet there remained a goodly quantity of liquid sloshing about! ???
Using a 60ml syringe used to feed cholostrom to young weak and or sickly lambs, I then removed a further 250ml of liquid/sludge from the bottom of the tank. :( Unless you remove this stuff, due to the c**p design of 'form ruling over function' that Yamaha employed on this tank design, you will get rust holes in the bottom of the SRX tanks. ??? At present the tank is soaking in a solution of kerosene based degreaser and boiling water, up to the filler neck.
Syringes are available from any good vetinary or agricultural suppliers; this is an example online advert: Re-usable_60ml_syringe_catheter (http://www.fearing.co.uk/animal-health/syringes/re-useable-syringe-60ml-catheter)
Further installments to follow! ???
My regards, Bill
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are you planning to seal it? ive had good results with por15, if you buy the full kit, it comes with a degreaser and rust remover to use before sealing it.
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Aye john,
It will need some protection, but there is some "hot work" planned afore getting that far and some new paint. I don't see the point in making good the tank and retaining the fundemental design flaw to ruin all the graft. I will keep progress posted, but as you say elsewhere, there is a "stock" to be dealt with! ;)
My regards, Bill
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lol, aye, 'stock' to be sure!
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MMMMmmmmm! Compact and bijou, with multiple opportunities for advancement, or some such load of old codswallop! ;) Myford would be useful!
Whilst, having more spacious accommodation, the ability to rapidly fill it, is one I try to resist. :-X
I just need to look next door to see what a lifetimes accumulation of 'Grey Fergies' and associated implements can produce! ::) Spares are now arriving from the Emerald Isle! :-X
I hope that you find "good homes" for all the "treasure"!
My regards, Bill
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Thought I would resurect this for continuity sake, rather than anything else.
Having now removed the motor from the frame and stripped it to the parted crankcases, the effects of condensation and old oil in a motor are all too apparent!
A timing chain side main bearing, with at least 0.005" play in the races, slack lateral play and some movement in the vertical plane of the big-end bearing, an off-side layshaft bearing that can be made to lock solid when turned by hand with side thrust, an oil strainer half full of debris blocking the wire gauze filter, oil pump lobes that appear to have been nibbled by mice and the latest discovery of the 3 off-side mainshaft bearing retaining screws having been stud locked in place! :( Not even the air hammer gun has shifted them, let alone the impact driver and 2lb ball peen hammer! Heat will be applied, but I don't wish to add to my misery by warping the crankcase. The crossheads are looking secondhand; I think the left-hand drills in the pillar drill are going to have to do a turn!
Two images attached: crankcase strainer after prising open the cover and lifting the spot-welded mesh. The strainer contents including plastic film, stones, steel and aluminium flakes, cloth fibres, sealant and carbon. :( Hopefully I might be able to post a 'Smiley' in here soon! :-\
My regards, Bill
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Images of the main bearing/crank corrosion and sludge.
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Assembled 'dry' crankcase - barrel stud. There have been several of these throughout the motor, but not sufficiently bad to be seized! ???
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Sincere sympathies Bill. I now understand even more the dilemma you originally faced....Repair or replace. It just goes to show how bad an engine can be and still turn over, fire and work albeit not efficiently
My regards
Ian 😉
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Aye Ian,
It is not until you have the cases split and everything out that you really know what you have.
One small ray of sunlight was leaving the offside crankcase on top of the stove until a drop of spit boiled ::) and then applying the blow torch to the back of the countersunk screws from the inside of the case. Then with a nice sharp small cold chisel, a 2lb ball peen and Kat holding the case to the bench with the oven gloves, all 3 were persuaded to slacken off, with no muttering or dark thoughts.
Now to construct the puller to push the crank and bearing out of the left-hand crankcase. I am not paying £68+ for one of Yamaha's finest! More to follow.
My regards, Bill
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Keep up the good work Bill and Kat. I'm forever calling for Alison to come out to the shed to hold something down, ooh er Mrs :)
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OOOOH! You are a cheeky boy! ;)
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A wee postscript to this initial post about Gert, the Mono with the XT600E motor. This afternoon after much procrastination and the spending of a not inconsiderable sum of spondoolies, the Starter button was pressed and the motor barked into life! ;D ;D ;D However, I wasn't quick enough to nip up the bleed bolt on top of the oil filter chamber before a gusher had developed. ::) With ~300ml of green 20/50 sloshing about the floor, I stopped the motor, mopped up with plenty of sawdust, topped up the oil tank and then fired up again. ;D Sounded very smooth, with a right 'Bark' from the one-off stainless steel exhaust system purchased with the bike.
The tank, front mudguard and seat cowl have all been repaired, sprayed up with Honda PB184MU Granite Blue Metallic that uses black as the base coat. These have yet to have their fittings attached and then put onto the bike. However, I will post an image, but be aware that these are removed to save space on the Forum server after a while.
My regards, Bill
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Can't wait to see it Bill. I know what you have been through to get to this stage so I fully sympathize.
Best regards
Ian :D
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Yes I too am also looking forward to seeing the photos Bill 👍... cheers, Michael
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yeah!!!... get them foto's published Bill :D.....
I'm hoping to be in the same position with #1 by Christmas ( just not quite sure which Christmas).....
decided to follow my own advice and bite the bullet and lash out on a new oil pump .... but will reuse the oil strainer from the donor 400 engine.
what did you use on the crankcase faces Bill ?
pip pip
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Aye Steve,
Was supplied with a tube of Honda Liquid Gasket 1216e (grey colour) and used it on everything. Apply to cleaned (brake cleaner) surfaces, with a small artist paint brush to obtain a thin even coat on both surfaces (same if a gasket is involved). A light film of oil on one face before applying gasket can make it easier to separate the two parts at a later date.
Have finally used Honda product up/last ¼ of tube has hardened, so have used Loctite MR 5922 (black colour) on some joints, with the same methodology. Similar properties (temp range etc) and readily available from Halfrauds. Seems OK.
Cheap artist brush packs from 'The Range' provide a good supply of suitable brushes at a cheap price, they are also good for cleaning in nooks and crannies.
My regards, Bill
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The Mono ready for the MoT, fingers crossed I can ride it the 6 miles, without any teething gremlins! ;)
Before and after images.
My regards, Bill
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Lovely looking shed you have there Bill, bike doesn't look half bad too😉. Best o luck with the MOT
Cheers, Michael
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Aye Michael,
That's no my shed Michael that was the vendors. Thank you for the compliment.
My regards, Bill
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great job Bill... a proper BIKE, all bits married together nicely.... be interested in knowing how it rides
how's the MOT go ?
pip pip
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No MoT today! :( I think and hope that Halfords 20/50W along with the assembly lube that I use proved too viscous. Stuck clutch plates that refused to 'free off' even with the lever and engine case adjusters screwed out way beyond any cable free play! Engine starts and runs nicely, so far, but any attempt to engage 1st gear brought everything to a rapid 'Halt'! Would have worn the ball and push rod out in very short order! ??? So, side case off, Sod's Law the gasket decide to tear, another on order! Clutch dismantled and washed in brake cleaner and then lightly oiled with 10/40Wsemi-synthetic, ready for re-assembly.
When the 20/50 came out it looked remarkably free of "shiny bits", so hope I can get it right this time.
Bill
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Update on the clutch outer case gasket. OME gasket (XT600E) ordered rather than a 'pattern' and this has now been fitted. Having washed the clutch, oiled all the components with Morris' 10/40W semi-synth. assembled it all and then adjusted the pressure plate clearance. The latter is an absolute scunner, as the clutch acentuating lever, with it's pointer and the casting marker (part of the engine case) are buried beneath the starter motor! ??? Shine light beneath starter, push the lever forward with a screwdriver, whilst tightening the small crosshead adjuster on the other side of the bike and then holding everything in place whilst nipping up the lock nut on the adjuster. Slainte, to my wife, for the extra pair of hands! ;D
The OME gasket has an additional bead of sealant applied to the rear lower side of the gasket, this is where I had a pattern gasket blow through on Sally, with disasterous results, covering the whole of the rear of the bike in oil! ::) We will see what happens, but the extra couple of quid may give extra piece of mind. Image attached.
My regards, Bill
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life!!! bill.... gets in the way of plans..... hope it's all sorted
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It's no just life Steve! There is incompetence on my part in the whole sorry scenario! :-[ :-[ :-[
Having rebuilt the clutch, installed the outer case etc and re-filled with 10/40W, the engine fired up lovely, warmed through, knocked the choke off and it settled to a steady 1,100 rpm tickover.
So, grabbed the clutch, engaged 1st gear and STOP, DEAD! Nothing! Ruddy electrikery with the sidestand switch! :-[ :-[ :-[ I don't get it, so changed the wiring and "Hey presto!", engage gear and the engine continues to tickover, feed the clutch and off up the across the yard we go. Grab the clutch and everything does what it is supposed to, snick into neutral, release clutch, motor ticks over and all appears well, no wee leaks either. ;)
Another call to my local MoT man on Monday and we will see how we go.
Now for a Duke 450 in the roof of the workshop! :-*
#1 by Xmas?
Good health, Bill
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glad it's all sorted Bill, all the more pleasing when you get it fixed yourself (even if, as often happens with me, you happen to be the architect of the problem :-) )... just when you think you know it all, summat comes up behind you and bites you on the bum !!.
#1 by Christmas... nice idea ... but more likely to be Spring 19 to be honest....
pip pip
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Aye Steve,
Set off from the house in the gathering gloom for an MoT at 16:00hrs, within 2 miles it was persisting heavily and then turned to sleet! :( Arrived at the garage and greeted like a long lost bodach, with water streaming off me and the Mono. Half an hour later, after a few 'Beeps' of the horn, a couple of blips of the throttle and a whole lot of tugging, pulling and squinting down straight edges I was presented with a 'PASS' for the Mono. ;D
The return canter in the dark to home was at a steady canter behind some cars, which held us back a bit, but with a clear sky (4°C). However, the engine revs up to 4,000rpm in all the gears and lopes along at ~60mph+ with ~3,500rpm on the clocks. Already given it a sluice with clean water and a blow-dry with the leaf blower to get rid of the crud, salt and water, before going back in the workshop.
We will see how it goes.
Toodle pip, Bill
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good news Bill..... 10 out of 10 for flogging through the cr*p weather..... I'd be besides myself with grief getting the machine covered in cr*p on it's first outing.
pip pip
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Aye Steve,
The bike is rebuilt to use, not be pimped out and then gawked at, it's an SRX Mono with an XT600E motor in it and we'll have run out of petrol by the time I snuff it, so get on them and ride them. The youf of today don't get that pleasure unless they are really committed and with the driving skills of many on the road at present, you need to be committed! ???
My mate was round for a blether and tea today after a 3 hour canter in the rain, on flooded roads riding a BMWF650 that has been the length of the Americas and it looks clean and tidy beneath the usual road clart. Hose it down and then use the leaf blower to dry it off, before going into the house and getting your own gear off. The mug o' tea and maybe a nippy sweetie always taste better! ;)
Good health, Bill
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You're right Bill .... I remember flogging back from the TT in 2000, got off the ferry at 10pm, by the time we cleared Liverpool it had started to rain .... got geared up under a bridge .... rained all the way back to Norfolk ..... #1 Son was on his morini, other 2 were on SRX's.... we stopped for fuel once ...
When we got home Son said 'and you used to do this all the time did you?'..... 'that was the worst ride of my life' !! (admittedly the lights on the morini were the usual 1960's Italian rubbish, so he had to ride behind me and in front of the other 2).... my feelings were.... that was a good ride, everything worked well, no hiccups.... a cup of coffee with a 'splash'... and all was good.
will be hoping to complete #1 before the Christmas break.... you've spurred me into action :)
pip pip
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;D Just think of it as a rivetting exercise! ;) And you've temperatures of 12°C plus at the moment, whilst we have had nothing above 5°C for the past 3 days, with autumnal gloom to match, so you'll no get frost bite out in the workshop.
All the best, Bill
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The Mono now has over 200 Km on the clock after further runs this week, thanks to the "No bad" weather and dryish, with little salt on the roads.
I managed to drop the bike on my gammy leg, attempting a tight 'U' turn to return to a filling station I had just passed as it spluttered with fuel starvation! The engine cut out on the apex and with no forward impulsion, the bike and I toppled in a heap! :-[ Silly old fool! However, my leg was under the bike and apart from a muddy and misaligned mirror, the bike is fine. I have a bruised shoulder and the gammy knee took the weight of the motor and is now a nice canary yellow! ???
Today Kat and I took both the Mono and the Bros out, it was Kat's first run on the Mono. Gently, gently, but she enjoyed riding the bike and I think will get the hang of it. Arrived home and as usual when running a rebuilt bike in the chain needed adjusting, as did the head race bearings, just a tweek. If left, it would have pitted the races and whilst I don't mind the job, replacing them can get the air a bit "blue"! ;) Oil etc. OK and no other loose fixings or leaks. Touch wood! :-X
Image attached of the pair of machines together and although they appear black, it is in fact a lovely dark blue metallic glaze over the top of a black base coat, with 6 coats of lacquer over the top. Pity the sun isn't shining to show it at its best.
Toodle pip, Bill
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Nice pair you have there Bill.... (ooo eerrr vicar) hope the legs mends up ok, take it easy.
Cheers, Michael
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Aye Michael,
Thank you for your compliment. As for the leg and shoulder; shoulder is improving as is the leg, a wee 2 mile walk today! But it reminds be that I don't bounce as I used to and need to keep centrifugal forces working for me rather than gravity taking over! ;)
Good health and my regards, Bill
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couple of posers!! :) , even the backgound looks good ... nice job there Bill .... if i bring #1 up to you, i'll have the same job please.... maybe pick it up end of Feb?? :)..
pip pip
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Aye Steve,
Thank you for your compliments. No room in the workshop I am afraid, as #1 Duke (1974) is getting rebuilt and #3 Duke (1975) has been exhumed from the tea chests beneath the plastic cover for assessing! Asphalt Lake for cash! ;)
As the weather was no bad and unseasonably mild today, Gert the Mono was out for another canter. About 80 miles and revs taken up to 4,500rpm for a short burst in 4th gear!
With an XT600E gearbox, using a gearbox sprocket of 15 teeth and a rear wheel sprocket of 41 teeth, same as when acquired, Gert appears to be over geared (17" rim with a BT45 tyre). Heading into a headwind (4, gusting 6) today caused problems and the step between 4th and 5th is really noticeable. Below 3,500rpm puts a strain on the chain, gearbox and the bottom end, you can "feel it"! ::) Also, the engine lacks tractability in 1st gear at low revs. :-\ The standard gearing for an XT600E is 15/45 teeth. So, I will be investigating a 43 tooth rear sprocket in the near future and hope to find the "sweet spot" at that. I will report on the outcome later.
Toodle pip, Bill
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That's 1,100Km plus since the rebuild and the reduction in the final drive ratio, by increasing the rear sprocket size from 41 to 43 teeth has proved succesful (15:43 rather than the 15:45 standard of the XT600E).
The last run this week was a circular route including Auchterarder, Aberfoyle (tea, with steak & Stornaway black pudding pie), before tackling the Dukes Pass, then Strathyre, Lochearnhead, Comrie, Crieff and then home. About 110 miles in all; some of the roads are a bit rough, with gravel up the middle and a fair old bit of cow/mud near gateways and farmyards. But a grand wee run.
Final close up of the Mono attached.
Thank you for the encouragement to you all on the forum.
Bill
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Great bikes those two, thanks for the lovely pics and sorry to hear that it was your bad leg the bike fell on. I don't suppose my wincing will be of any help to you!
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Aye mthee,
Thank you for your compliments. As for my gammy leg, whilst acquiring it was not my doing, me dropping the Mono on it was all my own doing. After this past weeks cantering it appears to be healed, but definitely doesn't appreciate sideways pressure on the joint! :-X But, at least I can still swing a leg over the seat and kickstart a lumpy single! ;D ;D ;D
Good health, Bill