Project: R1 Engine Overhaul - SORTED

[Fizzer Thou]

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture008.jpg

Looks good on the outside,but unfortunately it was down on power.

After replacing the worn clutch,changing the shims to adjust the clearances,replacing the spark plugs and balancing the carbs,I was told by my friend that the bike still had a problem off idle.
I had not heard or ridden the bike beforehand so did not know how bad the problem was.When I had been balancing the carbs I had noticed that there was a bad smell of petrol coming from the crankcase breather.So,after performing a compression check with a hot engine,the results showed that the rings were in need of replacing.Not easy on the R1 engine as the liners are part of the top crankcase.
First things first,I have taken delivery of the engine as the crankcases will need to be split.

And so it begins

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture010.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture011.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture012.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture013.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture015.jpg

In the last pic there is the AIS pump,which injects filtered air into the exhaust manifolds so as to burn any hydrocarbons unburnt by combustion.It might just have to go,as it causes gas analysers to be given a false reading when engines are run on a dynomometer.I have done this on my own R1 but is not a straightforward job.Luckily I have a lathe where I can make my parts,but if you wanted to buy the plugs required to blank off the AIS ports from the USA,they are quite expensive.

https://i666.photobucket.com/albums/vv23/WiNot_Rhencullen/Workshop/Picture446.jpg
https://i666.photobucket.com/albums/vv23/WiNot_Rhencullen/Workshop/Picture447.jpg
https://i666.photobucket.com/albums/vv23/WiNot_Rhencullen/Workshop/Picture451.jpg
https://i666.photobucket.com/albums/vv23/WiNot_Rhencullen/Workshop/Picture457.jpg

I have been asked to get this engine done ready for the TT races in June,but I reckon I could get it done by the beginning of May in time for the Mayday Run.
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Just talk bikes.What else is there?

Always have a 'Plan B'

[trippz]

Would love to see more on this, I'm really into mechanics and such. If I din't lack space I would have probably bought a older CG just to learn on.
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Don't take what I say seriously, I'm a F&*cking idiot

[Werny]

Do all R1's have that AIS thingy or is it a US import and needed for their emission laws?

Also, potentially cool thread

[dangerousdave]

excellent work .... will be following this
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1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

[Sako]

will be following ths thread.

[P.]

When you get bored theres a lovely GSXR750 engine you can get your hands on to have a fiddle if you wish

[Fizzer Thou]

[DrDonnyBrago]

Watching with interest, keep up the good work .

[HD]

How did you fit those blanking plugs?

Looking good though!
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Rusty '02 Vito Camper + CBR600F3

[Fizzer Thou]

The adapters for the AIS pump are only an interferance fit so I machined the plugs accordingly and once fitted have stayed in place without any problems.

Major progress today while I was awaiting for parts to be delivered for another project.

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture022.jpg

This is the AIS pump,a complicated piece of mechanical mayhem that when it goes wrong costs lots of money to replace as it is irrepairable.The easy solution is to just remove it and to blank off the ports.

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture021.jpg

So,pump removed and cam cover off exposing the cams

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture020.jpg

Timing rotor cover off

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture027.jpg

Cam journal covers off

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture029.jpg

Cams out

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture030.jpg

Cam followers or inverted buckets exposed.These have the clearance adjusting shims beneath them so I always use a good magnet to remove both the bucket and the shim at the same time

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture033.jpg

I utilise this for holding the buckets ready for reinstallation

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture034.jpg

The last bucket waiting to be pulled

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture037.jpg

Waiting somewhere to be stored safely

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture039.jpg

Cylinder head off after removing every nut and bolt of all differant sizes,some 5mm allen bolt,two 14mm dome nuts and several 6mm hex blank nuts.It helps to have the right tools

Oh dear.The following pics are what I found when I looked into the bores of each cylinder.I will let the photos explain

https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture040.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture041.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture042.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture043.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture044.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture045.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture046.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture047.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture048.jpg
https://i1073.photobucket.com/albums/w384/Rhencullen5/Picture049.jpg

With this much damage to the liners I am not surprised that there was so much steam and unburnt petrol being pushed out via the crankcase breather.As the liners are part of the top crankcase there is no option other than to have to source another set of cases.These are line bored at the factory and cannot be mixed and matched,so if a suitable set can be found it will mean swapping many parts over from the source engine to the new cases,together with the likelihood of new piston rings and main bearing shells.
____________________
Just talk bikes.What else is there?

Always have a 'Plan B'

[CHR15]

are they iron or nikosil ali?
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Fizzer Thou]

Nikasil.I doubt that they are even worth bothering about.The cracks may well have gone all of the way through which would explain how the gases were being pushed out through the breather,up into the airbox and causing a major bog just off idle.My friend did say that once the engine got over this bog the power was massive.Just think what it will feel like with it all sorted
____________________
Just talk bikes.What else is there?

Always have a 'Plan B'

[CHR15]

thought so, just surprised they've actually held in one piece with cracks like that!

bet a whole engine wont set you back much more than a decent set of cases?
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Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[waffles]

OK, I have to ask..... What would cause all of the liners to crack like that?
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Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[chris-red]

[P.]

Join the queue

[Fizzer Thou]

[Sako]

that damage is shocking, not surprised it wasn't running to great!

good luck getting her sorted out.

[evoboy]

Is the suspected piston ring damage in all of the bores or just the damaged ones? (or are all 4 cracked?).
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Suzuki GT250 x7------- Fazer 600------CB250RS------Aprilia Rally 70----- Bandit 600

APT Motorcycles

[Nick 50]

[Fizzer Thou]

[binge]

This thread is made of so much win!

[StormCrow]

Made of win? Not at the moment unfortunately - it's a nice centrepiece for the front room though!

Looking forward to seeing the progress (assuming the OP's friend decides to carry on with the resto - I'm hoping he / she will!)

[speedy]

i used to run a malossi 172 cylinder kit, this kit also had a nikisil liner and came (bran new) with honing marks

[evoboy]