XRV750 Re-build

[MCsanandreas]

two months? not good. on another website i use i bought some bicycle bits from another forum user,one month later nothing!
i can understand how chuffed off you must be.

[Wingnut]

Soda blast the engine if you have to ,but allot of the engine is covered up and a wire brush gets most of the baked on crud.

crank cases sand them down and polish with auto solve or paint - i painted mine with hammerite and they are fine.

[wigs_1]

Right then, been on my hols and eventually got the bike back from the frame straighteners the other week.

They've done a good job straightening it though by all accounts it was pretty tough going. Apparently there is a lot of strength / spring in the frame. Makes me wonder how hard it was crashed to bend it in the first place.

Anyway, all straight now, here are some piccys.

Front tube:



Top tubes:



Engine now out:




How I loosening the rotor bolt. Took me a while to figure out it was a LH thread....... Lent the Haynes to my Dad and he's on his hols. Should have it back for tomorrow tho....
Been trying to source a flywheel removal tool on the cheap but an M22 x 1.5 pitch bolt isn't easy to come by.



Was in the Honda dealer today too, a new output shaft is £108 excluding VAT!!!! Seems a bit pricy....

Should hopefully have the motor in bits by the end of the week so I can start getting the casings done.

[Rusty]

Try this

00-074
HONDA PULLER 22x1.5

£7.73 inc. vat@17.5%

Price: £6.58 (Excluding: VAT at 17.5%)

Quantity:





Off Road Only Ltd PULLING BOLTS



good luck with the rebuild..

[wigs_1]

Thanks Rusty. Just bought one of those earlier. £11.34 inc delivery. Should have it by the end of the week.

I was holding out for the lady who supplies our works with fasteners however because its not a standard size so they'd have to make one or more likely make 10 or 20.

Chris

[Rusty]

Clad you got sorted

I will have to invest in one myself as i need to strip and rebuild my @ as soon as i get back into the workforce

So keep us posted on your progress and don't forget, plenty of pics please.

Good luck
Gerry

[wigs_1]

Flywheel off.

RHS engine casing off. Clutch partly dismantled. Now come across some problems and could do with some help.

My Haynes appears to be lost in the post. It was posted lunchtime Monday First Class however it has still not arrived, so I have some questions if anyone can answer them.....

Clutch nut, 22mm socket (after removing the springs). LH or RH thread?

Still need to tackle the heads but not sure where to start
- What order do I loosen the bolts (sometimes this is important)?
- Is there a technique to loosening the camchains? Or do I have to split them? Is there a soft link? Can I get new links off Honda?

If anyone works in the Edinburgh or Bolton Post Office Delivery Offices please could you find my Haynes?

Cheers, Chris

[wigs_1]

Progress to date.

Good news, the Haynes arrived Saturday allowing me to progress.

Bad news, I struggled and failed with the clutch, absolute b&%$£d of a thing, I bolted a bicycle spanner to the clutch to lock it up, then bolted a metal bar to the engine sprocket but still could not remove it.

Bicycle spanner on clutch (works well).



The metal bar & sprocket, a not insubstantial piece of metal, now bent. Clutch still fitted.....



The cylinder heads are off, I appear to have some interesting combustion issues. Quite a lot of deposits too. Light coloured exhaust valve not the best fit on the seat and will definately need lapped in.



Barrels off, pistons out.



Pistons have been stripped of rings ready for cleaning, rear cylinder head stripped of everything again ready for a clean up.

Apart from stripping the front cylinder head the clutch is the only thing that now stops me progressing further. Checked the Haynes and there is no mention of a LH thread (it mentions it for the alternator) so I am going to take it to the Honda dealer to get it loosened before I break something. On the plus side I recon I've put a good 300+ Nm through the gearbox and its not broken so it must be pretty strong.

If anyone has any suggestions on how to deal with the clutch they would be much appreciated (and yes, I have un-peened the clutch nut......)

Cheers, Chris

[mad4it028]

impact gun?

[wigs_1]

impact gun?

Don't have one (or a compressor).
But they're on my birthday list......