VTR1000 engine rebuild.

[serlant]

I replaced the engine in my VTR1000 2 months ago, was on about 70k miles, and had developed a slight rattle when cold that I didn't like the sound of, replaced the engine with a £320 ebay unit that apparently had 27k on it. It was like night and day with the difference in smoothness.

haveing finally got around to getting the old engine home from my mates on monday the de(con)struction of the old engine has begun.

this is the first thing I noticed awry after taking the cams out (this is the head bolt closest the cam chain tunnel)
https://i191.photobucket.com/albums/z170/serlant/IMAG0059_zps1cc7df3d.jpg

front piston
https://i191.photobucket.com/albums/z170/serlant/IMAG0061_zpsa530656d.jpg

rear piston
https://i191.photobucket.com/albums/z170/serlant/IMAG0062_zps28aacc45.jpg

the pistons are pretty clean for the mileage its done.
one head
https://i191.photobucket.com/albums/z170/serlant/IMAG0066_zps4ba355e8.jpg

other head
https://i191.photobucket.com/albums/z170/serlant/IMAG0067_zps6ae2cb5e.jpg

the heads are going to be cleaned up and the valves and seat re-cut with 3 angle I think.

big end main bearings
https://i191.photobucket.com/albums/z170/serlant/IMAG0069_zps2d9b5a1f.jpg
https://i191.photobucket.com/albums/z170/serlant/IMAG0071_zps403a99ee.jpg

as it stands at the moment.
https://i191.photobucket.com/albums/z170/serlant/IMAG0072_zps3edde3e1.jpg

just awaiting a clutch holding tool so that I can get the clutch centre nut off then i'll split the cases.

rear piston after a whipe with a piece of kitchen roll
https://i191.photobucket.com/albums/z170/serlant/IMAG0073_zpse1bdb1ad.jpg

front as it came out of the lump
https://i191.photobucket.com/albums/z170/serlant/IMAG0070_zps30c3f09c.jpg

its pretty easy to get the pistons out of the lump with the cases not split but I wouldn't fancy getting a torque wrench in there on re-assembly!
____________________
04 CBR1000RR, 1995 Husqvarna TE410, 1998 VTR1000(Sold), 1990 XJ600(sold), 1996 KH125(dead and sold)

[Clutchy]

Pistons look good for age, assuming they weren't swapped out at an earlier date, still a cool thread!
____________________
Malaguti F12 Phantom-Dead, Suzuki AY50- Dead, NRG power DD LQ, CBR125.
*33 BHP restriction up on 10/12/14* Current bikes/car: SV 650 S/ MKIV GOLF
Guide to pass your test with no lessons!

[serlant]

Well the clutch holding tool arrived today, so I set at the clutch centre nut again but was un-successful in removing the nut still, It would seem I just don't have the minerals as I hung off it with my breaker bar with another 12" extension ontop of that and it didn't budge, so I put that on the back burner for the moment and continued with the the bits I otherwise had access too. I removed and labelled up all the buckets and shims, put some plugs in and filled the combustion chamber with paraffin to try and loosen up some of the carbon.

some scoring on the rear barrel, the middle left one seems major but the others seem minor, the big score seems to have been cause by some damage to the piston?
https://i191.photobucket.com/albums/z170/serlant/DSCF0691_zpsae92cbd4.jpg

this is the corresponding mark on the piston which lines up with the big score, it looks like something has hit the piston or it was dropped before assembly, as it has pushed the piston material upwards into the crown area and judging by the size of the nick in the piston if it was something in the cylinder that caused it it would probably has caused a lot more damage.

https://i191.photobucket.com/albums/z170/serlant/DSCF0692_zps4da79b59.jpg

gudgeon pin looks to have taken some abuse on the rear pot.

https://i191.photobucket.com/albums/z170/serlant/DSCF0684_zpsb3ced927.jpg

there is a corresponding black mark on the con rod on the bottom of the small end bearing.

https://i191.photobucket.com/albums/z170/serlant/DSCF0687_zps89f3a79b.jpg
____________________
04 CBR1000RR, 1995 Husqvarna TE410, 1998 VTR1000(Sold), 1990 XJ600(sold), 1996 KH125(dead and sold)

[P.]

Cool stuff How did you remove the con rods? Cannot see where you could access the bottom of them to unbolt

Still, keep the updates coming, I've oddly started enjoying V twins

[TUG]

Twins are awesome!
I miss my VTR1000F
____________________
Haz ER-5, innit!

[serlant]

the conrod bolts you can just about get at through the sump, theres some oil pipework thats in the way but you can just work around it.

The rear cylinder you can do with a ratchet and 10 mil socket, the front conrod you can get to one bolt but the other is blocked by the oil pump, I ended up using a unversal join piece at a right angle and undoing it that way. I can't see any way to get them torqued up again though haha!

got the bottom end apart last night after getting the clutch nut off. took me a little while to split the cases until I realised there was a sneaky little 10 mil bolt hidden behind the clutch below the rear cyclinder still done up. came apart easily once I removed that bolt! I must have checked 10 times to make sure I didn't miss any!

the crank journals don't look too bad.
clutch side
https://i191.photobucket.com/albums/z170/serlant/IMAG0083_zps52cbba57.jpg
https://i191.photobucket.com/albums/z170/serlant/IMAG0081_zpsf3a922b5.jpg

flywheel side
https://i191.photobucket.com/albums/z170/serlant/IMAG0082_zpsc17c8c6a.jpg
https://i191.photobucket.com/albums/z170/serlant/IMAG0080_zps1a071fe2.jpg

crank looks alright although there is a strange mark on the big end surface, looks like something in the metal (impurity?)
https://i191.photobucket.com/albums/z170/serlant/IMAG0085_zpsfb0f6463.jpg
https://i191.photobucket.com/albums/z170/serlant/IMAG0086_zps9af68c9e.jpg
https://i191.photobucket.com/albums/z170/serlant/IMAG0088_zpse7670cb4.jpg

how the bench looks by the time I was finished last night (photo was taken at 11:45! Dedication!)
https://i191.photobucket.com/albums/z170/serlant/IMAG0084_zpsf3439967.jpg

Next is to remove the valves and springs and see about getting the valves and seats re-cut, I did a leak down test with parrafin in the combustion chambers and one cylinder lost about half the parrafin over the course of 2 days, one either didn't loose any or an imperceptable amount, so they're both ok (last time I did a compression check was 179 and 183psi on the cylinders) so that was ok but might aswell get a fresh cut while its all out.

then its just waiting while I buy parts and decide what to do next.
____________________
04 CBR1000RR, 1995 Husqvarna TE410, 1998 VTR1000(Sold), 1990 XJ600(sold), 1996 KH125(dead and sold)

[serlant]

Well the project is still going, albiet slowly. got both heasd sorted and ready to bolt on, all valves lapped in, cams re-installed and shimmed to loose side of tolerance. decided to take the oil pump apart as it looked a little scratched on the side of the rotor. needless to say its Fecked! think i'll just buy a replacement from davidsilver (£75) for peace of mind instead of a used one.
https://i191.photobucket.com/albums/z170/serlant/IMG_20131215_163007_zps27dfb83e.jpg

bits arrived, crank journals x2 and rod shells x2, 4x new rod bolts and a new clutch centre nut
https://i191.photobucket.com/albums/z170/serlant/IMG_20131215_230844_zpsc2bcf1f5.jpg

spent about 3 hours with some brushes, some paraffin, and some rags and cleaned all the dirt off the outside of the engine, any marks now left on it are where the corrosion has eaten through the paint.
https://i191.photobucket.com/albums/z170/serlant/IMG_20131215_230924_zpsa17b817a.jpg
https://i191.photobucket.com/albums/z170/serlant/IMG_20131215_231015_zps78538558.jpg
____________________
04 CBR1000RR, 1995 Husqvarna TE410, 1998 VTR1000(Sold), 1990 XJ600(sold), 1996 KH125(dead and sold)

[Bullet]

looks good! But seeing as its in bits anyway, why dont you get it all aqua blasted? its not too much money and would be mint afterwards
____________________
nonstop unicorns vomiting sunshine pills into a rainbow toilet
-------------------------------------------------------------------------
past: ZXR750 J1, K1 & H1, GPX600R, Yamaha Radian. present: ZXR750 J2, SP-1, CB350