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Crankshaft / Engine help

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Dave C
L Plate Warrior



Joined: 29 Mar 2010
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PostPosted: 14:53 - 29 Mar 2010    Post subject: Crankshaft / Engine help Reply with quote

Hi all, looking for some advice on a crankshaft.

I have a low mileage ER5 that has suffered from crankshaft failure due to lack of oil (long story).

I have disassembled the engine and found out exactly what is wrong: Where the big-end attaches to the crank, the sleeve (correct term?) has disintegrated.
Sadly this has damaged the part of the crank that these hold on to. The damage is fairly minimal - scratches that are quite fine and not that deep, but can be felt when running a finger across it. The rest of the crank is fine, including the other sleeve for the other big end (only a 2 cylinder).

Am I correct in thinking that even with these hairline scratches I need it reground and new special / measured sleeves put in? If so, can anyone recommend me somewhere, as I'm having difficult finding somewhere Sad (I'm in the West Midlands)

In addition, is it worth having the little-ends done while the engine is apart?

I have the complete gasket kit read for reassembly, but I'm unsure on if I should have the cylinder head skimmed? The pistons look a bit worn and I was considering replacing them too (I can post pics if anyone would be willing to give me comments on them?). Having only just broke 10k miles though, I'm thinking of just cleaning them up and putting a new set of rings on them? any comments?

You'll have to excuse all the newbie questions. I had pretty much wrote the bike off and this was only ever intended as a learning project. I've found nothing too complex so far but are unsure on all of the above. I'm sure that once I've figured out what has to be done, I'll have no major problems Smile

Any help would be hugely appreciated.

Cheers
Dave Very Happy Thumbs Up
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Kickstart
The Oracle



Joined: 04 Feb 2002
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PostPosted: 16:09 - 29 Mar 2010    Post subject: Re: Crankshaft / Engine help Reply with quote

Dave C wrote:
Where the big-end attaches to the crank, the sleeve (correct term?) has disintegrated.


I take it you mean the big end bearing shells. If they are that bad I would be surprised if the crank is as lightly damaged as you say (and it could quite easily have left enough vertical play in the con rod that the piston has touched the valves).

I would also expect the cam bearings to have suffered by that stage.

There are a few people around who might be able to check and repair the crank (eg, SEP in Kegworth). However given how common ER5s are it might be more financially practical to just get a replacement engine 2nd hand.

I would not expect the pistons to be worn noticeably within 10k on a low stressed 4 stroke.

All the best

Keith
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Dave C
L Plate Warrior



Joined: 29 Mar 2010
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PostPosted: 16:40 - 29 Mar 2010    Post subject: Reply with quote

Thanks for the reply Keith Smile

Maybe disintegrated was too strong of a word. They were there, just thinner than normal and had sharp edges.

I'll grab some pics of both if anyone would be so kind as to offer some input on them?

Cheers
Dave
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BanditsHigh
Worse than a woman



Joined: 21 Mar 2005
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PostPosted: 17:06 - 29 Mar 2010    Post subject: Reply with quote

The shells will be damaged fairly quickly if oil pressure is lost ... it's the fine film of high pressure oil which the crank/conrods run on, not the actual metal ... hence if the oil fails the shells will be damaged pretty quickly.

Not only the crank can be damaged by oil pressure failing but the conrod as well ... as the shell gets pounded by the conrod running directly on the metal it'll thin out, thereby allowing the conrod to move vertically more than it should ... this can ovalise the conrod shell bearing surface in severe cases.

As suggested by yourself, a few pictures will give everyone a better idea of the damage and what needs to be done Thumbs Up
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