If something has come adrift in the bottom end, you are going to have to split the cases to find the culprit!,
Can't kick
- Thread starter RoloTheMan
- Start date
Okay, I am planing on doing this my self one step at a time. I have never done it before but have been watching videos and going through forums and feel like I could do it myself.
Since I have never done this before I just wanted some advice of What kind of tools are MUST-HAVE, Will I have replace all of the bearings and rubber gaskets, or can I reuse what I have since I'm hopping I'm only going to clean it out, and just any advice I can get for a first time
Tanks to everybody for replying and trying to help me out
-Rolando
Tanks to everybody for replying and trying to help me out
-Rolando
That piston isnt broken, you still have another issue, like id suspect lower rod bearing came unglued, thats super common, an parts will travel up past the piston an score cylinder, if top end is off an crank still dont turn easy keep investigating.
since i just did a full rebuild for my buddy 2 weeks ago, this is fresh on my mind, i listed reasonably priced tools from ebay. if you're not going to use these daily, they will get the job done.
if expensive tools give you morning wood, by all means go buy snap-on or craftsman
you'll need these at least..........
impact screwdriver:http://www.ebay.com/itm/Impact-Scre...S_Srewdrivers_Nut_Drivers&hash=item3ce14cbbcc
flywheel remover: http://www.ebay.com/itm/27mm-Flywhe...Motors_Automotive_Tools&vxp=mtr#ht_2077wt_917
clutch holding tool: http://www.ebay.com/itm/Tusk-Clutch...Motors_Automotive_Tools&vxp=mtr#ht_1474wt_873
snap ring pliers: http://cgi.ebay.com/4-in-1-Snap-Rin...368&item=360605127528&pt=Pliers#ht_7025wt_758
harmonic balancer puller set: http://www.ebay.com/itm/46-PC-HARMO...ors_Automotive_Tools&vxp=mtr#ht_331wt_919plus
plus m8 bolts long enuf to reach the 2 threaded bungs down in the flywheel side case
torque wrench: http://www.ebay.com/itm/NEW-PITTSBU..._Hand_Tools&hash=item35ce18e669#ht_1409wt_883
yamaha, honda, or three bond case sealant,
red, blue and green loc-tite,
brake cleaner
a full set of metric sockets and wrenches, both preferably 6 point.
optional.....
these help to jam the primary gear:
http://www.rockymountainatvmc.com/p/989/22841/Motion-Pro-Gearjammer?term=motion pro gear
allen head case bolts for reassembly:
http://www.ebay.com/itm/YAMAHA-BLAS...Parts_Accessories&hash=item56681b0e48&vxp=mtr
metric allen sockets:
http://www.ebay.com/itm/NEW-3-8-DRI...92818620?pt=US_Hand_Tools&hash=item5660e529bc
tusk crank puller, only needed if you don't follow the vids below:
http://cgi.ebay.com/ebaymotors/Tusk...t=Motors_Automotive_Tools&hash=item3a8c485fff
the KOR assembly vids
http://www.blasterforum.com/threads/kor-engine-assembly-vids-no-crank-puller-needed.51169/
you'll need a propane or mapp gas torch and a 2" trailer hitch ball to sweat the crank in like shown in the vids
i would never open a bottom end without at least replacing the crank main bearings and seals, and all new OEM gaskets everywhere.
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To get the case apart, these are a must list of tools that you will not have laying around
- Tusk clutch/flywheel tool
- Flywheel Puller
- Impact screw driver
- Cir Clip Pliers
- Yamabond 4 (putting the cases back together)
If you dnt have these tools, do not try and rig something up to work. You will waste time, energy and frustration, when those make the job so much simpler.
- Tusk clutch/flywheel tool
- Flywheel Puller
- Impact screw driver
- Cir Clip Pliers
- Yamabond 4 (putting the cases back together)
If you dnt have these tools, do not try and rig something up to work. You will waste time, energy and frustration, when those make the job so much simpler.
Last edited by a moderator:
since i just did a full rebuild for my buddy 2 weeks ago, this is fresh on my mind, i listed reasonably priced tools from ebay. if you're not going to use these daily, they will get the job done.
if expensive tools give you morning wood, by all means go buy snap-on or craftsman
you'll need these at least..........
impact screwdriver:http://www.ebay.com/itm/Impact-Scre...S_Srewdrivers_Nut_Drivers&hash=item3ce14cbbcc
flywheel remover: http://www.ebay.com/itm/27mm-Flywhe...Motors_Automotive_Tools&vxp=mtr#ht_2077wt_917
clutch holding tool: http://www.ebay.com/itm/Tusk-Clutch...Motors_Automotive_Tools&vxp=mtr#ht_1474wt_873
snap ring pliers: http://cgi.ebay.com/4-in-1-Snap-Rin...368&item=360605127528&pt=Pliers#ht_7025wt_758
harmonic balancer puller set: http://www.ebay.com/itm/46-PC-HARMO...ors_Automotive_Tools&vxp=mtr#ht_331wt_919plus
plus m8 bolts long enuf to reach the 2 threaded bungs down in the flywheel side case
torque wrench: http://www.ebay.com/itm/NEW-PITTSBU..._Hand_Tools&hash=item35ce18e669#ht_1409wt_883
a full set of metric sockets and wrenches, both preferably 6 point.
optional.....
these help to jam the primary gear:
http://www.rockymountainatvmc.com/p/989/22841/Motion-Pro-Gearjammer?term=motion pro gear
allen head case bolts for reassembly:
http://www.ebay.com/itm/YAMAHA-BLAS...Parts_Accessories&hash=item56681b0e48&vxp=mtr
metric allen sockets:
http://www.ebay.com/itm/NEW-3-8-DRI...92818620?pt=US_Hand_Tools&hash=item5660e529bc
tusk crank puller, only needed if you don't follow the vids below:
http://cgi.ebay.com/ebaymotors/Tusk...t=Motors_Automotive_Tools&hash=item3a8c485fff
the KOR assembly vids
http://www.blasterforum.com/threads/kor-engine-assembly-vids-no-crank-puller-needed.51169/
you'll need a propane or mapp gas torch and a 2" trailer hitch ball to sweat the crank in like shown in the vids
2 min late! but your list is better haha!
Last edited by a moderator:
Okay, so I kept digging and got the case split (Thanks Awk08 and jbuckster07). Everything looked fine and turned as I imagined it should except one thing. THE CRANKSHAFT!!
I was able to get it off of the case and could see the metal shavings I mentioned earlier at the bottom of the case.
The only thing that does not move is the "rod?". It seems to be stuck. I'm guessing I'm going to have to order a new crankshaft :/
Yep, you need a crank. See that slot in the rod? You're supposed to be able to see rollers in there. LOL BTW, the main bearings don't come with the crank. You have to buy those separately.
Thanks for the reply.
Will I also need a new top end kit or can I urese the same piston and rings.
The previous owner told me that it was bored to 240 how can I check this to make sure I buy the correct size piston and ring kit?
I have a few pics on the first page idk if any those are helpful or if I need pics of more specific area I can do it later
Dumb question. Did you remove the c clip holding the piston pin in or was it missing? If you pulled your top end off and the crank still will not rotate, split the case. You have no choice.
Heat up your cases and pop those main bearings out and toss them in the trash. Get new ones. Order a pro x rod kit and get that crank rebuilt. Than put it all back together.
Good job getting it apart! Bansheedave said it best in the post above. Also get some hex head case bolts if you don't already have them, and some yamabond. Lap the cases to make sure you have a good leak free fit.
Your getting there, and putting it back together is just as fun as taking it apart.
Your getting there, and putting it back together is just as fun as taking it apart.
