XRV750 Re-build

[wigs_1]

Ok then. Clutch is off, cases are split. Thanks to Dave at Two Wheels Honda in Edinburgh who came out with an air-gun to loosen off the clutch.

This was all done last week. The last 7 days has been a bit slow due to 30th Birthday celebrations.......

Clutch off


Gearchange mechanism & oil pump


Cases split showing gearbox / crankshaft / oil pump




Crud on oil pump gauze???


RH case


LH case


Now all I need to do is clean everything up, seal all the holes / bearings and have the casings blasted for painting.

Should have more progress in a week or two.....

Cheers, Chris

[Wingnut]

Ok then. Clutch is off, cases are split. Thanks to Dave at Two Wheels Honda in Edinburgh who came out with an air-gun to loosen off the clutch.

This was all done last week. The last 7 days has been a bit slow due to 30th Birthday celebrations.......

Clutch off


Gearchange mechanism & oil pump


Cases split showing gearbox / crankshaft / oil pump




Crud on oil pump gauze???


RH case


LH case


Now all I need to do is clean everything up, seal all the holes / bearings and have the casings blasted for painting.

Should have more progress in a week or two.....

Cheers, Chris

Now thats what I call a serious restoration - well done that man and keep it up should be a new bike with that work done .

Jonny

[wigs_1]

As you can see its been a little while since my last post (June 10).
I haven't stopped, I've just been delayed slightly....

Delays encountered.
- Had to do the garden (2 weeks)
- Lots of weddings (4 weekends)
- Work commitments (2-3 months)
- A lack of motivation during the really cold weather... (6 weeks)

Since my last post I have:

Thoroughly cleaned all the engine cases, bead blasted them to remove flaking paint, corrosion, dirt etc.
Unfortunately, despite my best efforts I was unable to stop the dirt and beads from the blasting getting into the ball bearings. These suffered very minor damage as a result so figured it'd be prudent to replace them so I now have a full compliment of new bearings ready to be fitted.

Getting 3 of the 4 bearings out was easy as I got an Arbor press for xmas.
The 4th was tricky as it sits in a blind hole, this was removed using a sawn-off 12mm rawl plug and some hydraulic gear at my local car garage.

I tried to source the bearings independently however the output bearing (next to the sprocket) is not an item readily available in the UK so would have to go to Honda anyway. The saving on the others wasn't worth it so I got the lot from Honda for £50. (Could get for £42 using different sources but not worth the hassle).

A full engine gasket kit from Honda is ~ £170!! or £85 from Wemoto. No contest there.

I also figured that a replacement driveshaft would be a good idea given the current one has done 35k and is partly worn and I plan on keeping the bike for a while. This was £117 from Honda (with 10% off)

The casings are currently getting their final coats of paint (3rd one on tonight) using POR-15 Engine Enamel. Painting has taken place in the kitchen where it is warm, much to the girlfriends delight....

Preperation for the engine was extensive and took days:
- Cleaned using a trimmed paintbrush and meths
- Pressure washed
- De-greaser, solvents, water and air blasted through ALL oil orifices and oilways to ensure there is no remaining debris.
- Surfaces prepared using POR-15 Metal Ready

Hopefully it will look ok when finished. The POR-15 engine enamel is pretty thick and the first two coats left brush marks when it dried (the tin says paint with a brush). For the 3rd coat I thinned the paint by about 15% and this made it very runny. It took a while to get used to however this is already looking better and its not set yet. I recon some light sanding tomorrow to get rid of some runs followed by the final coat. Maybe a light sand with 1200/1500 grit followed by rubbing compound and polish on the bits that you can see to finish it all off.

Hopefully the actual re-build should start on Sunday.

Other things I've done since my last post:
- Bought a 150 litre compressor + associated air tools, best thing I ever bought
- Bought a VFR800 to keep my hand in on 2 wheels, collecting Saturday woo hoo

No pictures yet, to follow in a week or two's time when I have more time to work on the PC and upload the pics.

Cheers, Chris

[magwa]

Just a word of warning......
any stray grit up hiding in any oilway anywhere will
WRECK
your engine, and as you got it into your bearings
you know where I'm coming from.

I never have any crankcases bead blasted for that very reason

There are companies that ultrasonic clean and soda blast
more expensive work
BUT
Zero chance of wrecking yout hard work

Good luck

[abyzfr6]

Keep up the good work.
I'm in a middle of same project (6 months...), i know what delay means...

[wigs_1]

Hi all
New gearbox output shaft fitted (make sure you get the tab washers correct, Haynes manual invaluable).
All crankcase internals installed I'm going to joint the crank cases on Wednesday night.

Question: Which sealant should I use for joining the cases? I have the following:
- Blue hylomar, non-setting
- Red haematite, part setting

Any comments / advice appreciated.

Cheers, Chris

[StumpyFingers]

Have you also got a proper gasket?
Would tend to go for the blue.

[wigs_1]

No proper gasket in the kit.
Haynes says sealant only.
Cheers

[wigs_1]

Put the cases together last night.
All going fine till I started putting the LHS bolts in.
One of them picked up some dirt in the thread. Looks like I missed running a tap down one of the holes.
Bolt wouldn't go in so had to split the cases to run a tap down it.
Bugger.
Didn't seem it at the time but this may be a blessing in disguise.
I didn't think I used a lot of gasket sealant but splitting the cases revealed that some of it had oozed into the crankcases. Not massively but enough to make me think that this was for the best....

Off out to the garage for the 2nd attempt.

[kennymact]

Hi Wig,s.....just been reading your thread and as I have just done the same with my yam xt 600 .......I used a compressor and rattle gun for the clutch removal all of what you know about now and as for the gasket goo I used original yam stuff and you really do need the smallest amount for sealing the cases.....so good luck and enjoy......I used mineral oil when I did my yam as I put new rings in and ran it for 60 kms to break them in and then changed the oil again and filter.