XRV750 Re-build

[wigs_1]

If anyone noticed before xmas I was looking for a replacement frame for my AT. It quickly became apparent that they are like hens teeth to find and my best bet is to get the frame straightened.

I rang this place (www.bikepaints.co.uk) who have a jig to straighten the frame, this should cost between £150 & £250 depending on how long it takes...... More importantly they're not too far away. Once its straight (if it can be straightened!!) the frame needs shotblast/powdercoated etc.

I also need to clean-up the engine as some of the paint has come off and the casings are corroding in places. Given that the engine will be out of the frame my thoughts are to remove the gearbox output shaft and replace the associated bearing as well as whatever rattles when the engine is in neutral, clutch out.
From what I can gather this will involve completely stripping the engine to get these parts out (got a load of threads bookmarked).

So, my thoughts are:
- clean the engine as best I can
- strip the engine
- de-grease the components (parts cleaner at work)
- get the externals shot-blasted
- spray externals with high temp engine enamel
- re-build engine & fit to frame

So, the questions:

- Has anyone any experience of shotblasting an engine? (actually using beads not grit, therefore softer)
- Should I look at ice-blasting (expensive)
- What (in the gearbox?) rattles when the bike is ticking over, in neutral, clutch out..? (goes away when you pull the clutch)
- What is a good engine paint to use?
- Should I spray the engine whilst in bits or re-build and spray as a one piece?
- Regards the output shaft, I am considering getting the new one nitrided and heat treated, this should increase the hardness significantly, hopefully it'll never need another......

I'll try and keep the thread updated with progress so that others can learn from the many mistakes I'm about to make...... but don't be surprised if it takes me a while, I'm not the fastest worker and at time of writing the car needs some work too...

Will try and upload some pictures too.

Chris

[chronyx]

No idea, but just wanted to say good luck, and one positive thing is that these jig places often get the frame better than it was at the factory - if it meets tolerances then they use it, whereas these places can get it spot on.

[BobA]

Some quick thoughts;


Maidstone Motoliner (who are brilliant at straightening stuff) quoted me £200 for straightening an RD07 frame. A friend (with a motorcycle business) has pre-warned me that frames with square tubes are a lot harder to straighten than round ones.

Output shaft bearing. Has it gone? Why do you want to replace it?

Rattling noise associated with the clutch could be as simple as the clutch plates have caused notches on the clutch basket. But it could be other things too!

You have to work out in your mind (financially) how much you want to spend on the bike and if you intend to keep it etc.

If you can get away without splitting the engine I wouldn't do it, as once you've started the costs could spiral if you start getting picky and deciding to do other things while it's apart (camchain, tensioner, gaskets etc etc)

I wouldn't have thought it would be advisable to blast an engine with any media without it being stripped, although if you were exceptionally carefull and plugged up every hole, there's no reason why you shouldn't. Have you looked at the cost of soda blasting????


Good Luck, and how about posting some pics???




Bob

[wigs_1]

Originally Posted by BobA

Maidstone Motoliner (who are brilliant at straightening stuff) quoted me £200 for straightening an RD07 frame. A friend (with a motorcycle business) has pre-warned me that frames with square tubes are a lot harder to straighten than round ones.

I'll have to see what they say when I get there. To me it looks as if the frame is relatively straight but twisted slightly just below the headstock.
I also heard that steel frames are more tolerant of straightening than alloy ones hence I think it'll be worth persuing...

Originally Posted by BobA

Output shaft bearing. Has it gone? Why do you want to replace it?

The splined shaft onto which the sprocket goes is reasonably worn so I thought that as the engine is out I'd change it. Thought I may as well do the bearing too. I know the chain has been over-tightened at some point....

Originally Posted by BobA

Rattling noise associated with the clutch could be as simple as the clutch plates have caused notches on the clutch basket. But it could be other things too!

You have to work out in your mind (financially) how much you want to spend on the bike and if you intend to keep it etc.

If you can get away without splitting the engine I wouldn't do it, as once you've started the costs could spiral if you start getting picky and deciding to do other things while it's apart (camchain, tensioner, gaskets etc etc)

I wouldn't have thought it would be advisable to blast an engine with any media without it being stripped, although if you were exceptionally carefull and plugged up every hole, there's no reason why you shouldn't. Have you looked at the cost of soda blasting????

As you can see in the pic the finish on the motor is poor hence the need to get it blasted. And if you do that it may need a strip. As well as this its a good opportunity to do the output shaft.....
Never heard of soda blasting, thats tonights research.



Help. I'm spiralling already....

Originally Posted by BobA

Good Luck, and how about posting some pics???

Thanks. This is where I am at the mo. Motor needs to stay in the frame for the straightening, will be replacing the swingarm too before I go.

Chris

[wigs_1]

Dropped the bike off for straightening this morning. Will get it back next Saturday. Fingers crossed....

[tserts]

I have that ratling in neutral as well, I don't think it's the discs or clutch. Please post if you find out the cause and, for extra kudos, the fix...

Good luck with the frame, the bike looks beaten, it would be great to get it back on the road...

[Wingnut]

Originally Posted by wigs_1

Dropped the bike off for straightening this morning. Will get it back next Saturday. Fingers crossed....

Should be fine . Best of luck with your rebuild enjoy it mate I am .

Jonny

[wigs_1]

Update: The bike is still getting sraightened. It wasn't ready after the 1st week, and again after the 2nd. Now it is 'straighter' however the top tubes have apparently moved downwards!!!

None of this sounds promising and theres nothing I can do other than hope for the best and cross my fingers......
And I'm about to go on my hols so I won't see it for a month now....