Post by cb250g5 on Jul 15, 2020 11:13:16 GMT 1
TLDR:
My Yellow F2/N2 with FZR 250 running gear...
As I mentioned a few weeks back, my HVCCycle ali kickstart broke, after many years of use, and I put the original cast iron one back on.
I was then plagued by an intermittent odd rattle, that I just couldn't track down, from the clutch case area. So I decided it had to come off for a gander.
Oh dear... There was enough play in the kick start idler gear for it to catch occasionally, I think the extra weight of the original kickstart was just enough to pull the shaft down sufficiently to catch.
Plus the clutch rubbers had worn to the point where I couldn't ignore them any longer, I think they were borderline when I built this motor 14 years ago.
Then I noticed I'd lost a base nut, and slight signs of base gasket blowing, so the top end needed to come off.
I'd bought the crank from Stan the Man as a rebuilt one 38,000 miles ago, so I decided it had better come out for a look.
So engine out and complete strip.
Trip to Norbos for Mitaka clutch basket & rubbers, new jap crank and all gaskets & seals etc. Top end unworn (to my surprise) so just new rings, little ends & circlips and a minor "hone" with a bit of oiled wet & dry. Replaced all gearbox bearings as well, but no sign of wear on old ones.
Changed the clutch window, as it had little cracks round the screw holes.
Had to make an oversized idler gear bush, at 10.5mm long to get rid of any play. Maybe the thrust washer had worn away a bit?
Put it all back together, and oil pissed out the neutral switch. Strange as I hadn't touched it (mainly because it's a right bodge of off centre screws due to something breaking in the past, before my ownership, looks like Stevie Wonder did the repair). I guess removing the selector shaft disturbed things. New O ring fixed this.
Fired it up this morning, to heat cycle the head gasket and bleed the oil pump. By heck, it's quieter than it has ever been, no rattles at all, don't think it's ever sounded this quiet since I bought it.
Hopefully I can re-tighten head nuts tomorrow, top up water, add tank & bodywork & get out for a ride soon, before summer, such as it is, is done with.
My Yellow F2/N2 with FZR 250 running gear...
As I mentioned a few weeks back, my HVCCycle ali kickstart broke, after many years of use, and I put the original cast iron one back on.
I was then plagued by an intermittent odd rattle, that I just couldn't track down, from the clutch case area. So I decided it had to come off for a gander.
Oh dear... There was enough play in the kick start idler gear for it to catch occasionally, I think the extra weight of the original kickstart was just enough to pull the shaft down sufficiently to catch.
Plus the clutch rubbers had worn to the point where I couldn't ignore them any longer, I think they were borderline when I built this motor 14 years ago.
Then I noticed I'd lost a base nut, and slight signs of base gasket blowing, so the top end needed to come off.
I'd bought the crank from Stan the Man as a rebuilt one 38,000 miles ago, so I decided it had better come out for a look.
So engine out and complete strip.
Trip to Norbos for Mitaka clutch basket & rubbers, new jap crank and all gaskets & seals etc. Top end unworn (to my surprise) so just new rings, little ends & circlips and a minor "hone" with a bit of oiled wet & dry. Replaced all gearbox bearings as well, but no sign of wear on old ones.
Changed the clutch window, as it had little cracks round the screw holes.
Had to make an oversized idler gear bush, at 10.5mm long to get rid of any play. Maybe the thrust washer had worn away a bit?
Put it all back together, and oil pissed out the neutral switch. Strange as I hadn't touched it (mainly because it's a right bodge of off centre screws due to something breaking in the past, before my ownership, looks like Stevie Wonder did the repair). I guess removing the selector shaft disturbed things. New O ring fixed this.
Fired it up this morning, to heat cycle the head gasket and bleed the oil pump. By heck, it's quieter than it has ever been, no rattles at all, don't think it's ever sounded this quiet since I bought it.
Hopefully I can re-tighten head nuts tomorrow, top up water, add tank & bodywork & get out for a ride soon, before summer, such as it is, is done with.
