ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 04-25-2010, 08:55 AM   #151
DisTech OP
Studly Adventurer
 
DisTech's Avatar
 
Joined: Sep 2008
Location: Seattle
Oddometer: 616
Quote:
Originally Posted by yondering
Glass beads in the oil and bearings would definitely be a concern, because it tends to get everywhere, but it will not embed in the cases. They would need to be very thoroughly cleaned though.

The finish you describe on your friends bike sounds like glass bead; it leaves a slightly shiny/sparkly matte finish, almost like a styrofoam take-out box, but less glossy. Not a dull surface like sand blasting though.
Walnut won't do anything for the corrosion in the cases; it's not a hard enough media. It is good for cleaning and paint removal, but won't significantly alter the finish of the aluminum.

DisTech, if you give up on the polishing, and want to go ahead and glass bead the cases, you are welcome to use my bead blaster, I'm just a couple hours north. You'd definitely need to remove the bearings first though, as you said; sounds like a real pain.
Thanks for the offer yondering, I may take you up on that. For pulling the bearings I just ordered this:

Mountain (MTN9001)
Pilot Bearing Puller


Features and Benefits:

When working space is limited, this type of puller is needed to remove flywheel pilot bearings from automobiles, trucks, and tractors
  • Only 7 1/2" long
  • Can also be used to pull bearings or bushings from generators or starters
  • Includes 1/2" to 1 1/4" ID Capacity jaws
  • Strength - helps pull out tough bearings
  • Short length - allows reach into tighter areas
  • Versatility - works on automobiles, trucks, and tractors
  • Made in the U.S.A.

There are lots of pilot bearing pullers but most have 3/4" ID jaws. The 1/2" ID jaws are required for most of the bearings in the case and took a little digging to find. I hope it works!
__________________
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)
DisTech is offline   Reply With Quote
Old 04-26-2010, 08:18 PM   #152
procycle
Beastly Adventurer
 
procycle's Avatar
 
Joined: Jun 2007
Location: Center of the DR650 universe
Oddometer: 2,216
Quote:
Originally Posted by DisTech
Thanks for the offer yondering, I may take you up on that. For pulling the bearings I just ordered this:

Mountain (MTN9001)
Pilot Bearing Puller
There are lots of pilot bearing pullers but most have 3/4" ID jaws. The 1/2" ID jaws are required for most of the bearings in the case and took a little digging to find. I hope it works!
The easier way to remove the bearings is to put the case half in an oven. Heat for about 1/2 hour at 350 degrees and the bearings will fall right out.

The oven works just as good when it's time to put the bearings back in. Heat up the case and just drop the bearings into their holes.
__________________
Clarke's second law of Egodynamics: "For every expert, there is an equal and opposite expert." - Jasper Fforde
www.procycle.us - Everything for your DR650 and lots of other great stuff!
DR900 Big Bore Stroker buildup
TurboDiesel Corvette - go to the end to start at the beginning
procycle is offline   Reply With Quote
Old 04-26-2010, 08:24 PM   #153
procycle
Beastly Adventurer
 
procycle's Avatar
 
Joined: Jun 2007
Location: Center of the DR650 universe
Oddometer: 2,216
Quote:
Originally Posted by yondering
Glass beads in the oil and bearings would definitely be a concern, because it tends to get everywhere, but it will not embed in the cases.
I have had great results blasting with soda. This is a special crystallized formulation of baking soda. Clean up after blasting is with hot soapy water. There's no concern about getting it the bearings because it dissolves in the water and rinses away.
__________________
Clarke's second law of Egodynamics: "For every expert, there is an equal and opposite expert." - Jasper Fforde
www.procycle.us - Everything for your DR650 and lots of other great stuff!
DR900 Big Bore Stroker buildup
TurboDiesel Corvette - go to the end to start at the beginning
procycle is offline   Reply With Quote
Old 05-08-2010, 05:27 PM   #154
DisTech OP
Studly Adventurer
 
DisTech's Avatar
 
Joined: Sep 2008
Location: Seattle
Oddometer: 616
93 DR350 - Removing case bearings.

The right half of the case was easy to get the bearings out because they could all be tapped out from the opposite side. The left half of the case is a different story because there are two bearings that can only be accessed from one side.

First I'm giving Jeff's oven method a try! Preheating to 350.


After 15 minutes the house smelled like motor oil casserole and one of the bearing dropped out!


I went up to 45 minutes and the other bearing was still tight in place. Oh well, 50% success with the oven!

Good thing for the backup pilot bearing puller. After a lot of farting around, filing the jaws so they would not just pullout without the bearing, success!


__________________
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)

DisTech screwed with this post 05-15-2010 at 08:24 AM
DisTech is offline   Reply With Quote
Old 05-08-2010, 06:39 PM   #155
Mezo
Banned
 
Joined: Nov 2008
Location: Brisbane,Australia.
Oddometer: 2,129
Thats' a nice little puller you guys make all the handy tools, we just get the usual cheap Chinese crap that breaks on its first use.

Like valve guides & valve seats, put the bearings in the freezer a day before & they go in real easy after you warm the cases.

Mezo.

Mezo screwed with this post 05-10-2010 at 02:07 AM
Mezo is offline   Reply With Quote
Old 05-09-2010, 09:02 PM   #156
DisTech OP
Studly Adventurer
 
DisTech's Avatar
 
Joined: Sep 2008
Location: Seattle
Oddometer: 616
Quote:
Originally Posted by Mezo
Thats' a nice little puller you guys make all the handy tools, we just get the usuale cheap Chinese crap that breaks on its first use.

Like valve guides & valve seats, put the bearings in the freezer a day before & they go in real easy after you warm the cases.

Mezo.
The trick was finding one that worked for 1/2" shaft. There's lots of them that start at 3/4".
__________________
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)
DisTech is offline   Reply With Quote
Old 05-09-2010, 09:30 PM   #157
DisTech OP
Studly Adventurer
 
DisTech's Avatar
 
Joined: Sep 2008
Location: Seattle
Oddometer: 616
94 DR455 - Case reassembly.

Bad news, the taller 6th gears from the early 250's are also being discontinued (like the 5th already is). I tried several different sources and I could find a 6th drive but no 6th driven.

Good news, no more waiting to build the 455!

Mezo the freezer sounds like a good idea, but I didn't want to wait overnight so I tried Jesse's suggestion. Use a torch to heat the case until it hot enough to bubble spit, and then the bearings will drop right in. Sure enough, the bearing on the crank almost felt loose it dropped in so easy.


When the Moon is in the Seventh House and Jupiter aligns with Mars then peace will guide the planets and love will steer the stars...


I used the countershaft and driveshaft assemblies from my 93 DR350S because the gears were in better shape than the 94 dirt model.


Ran through all the gears to make sure I had all the forks and cams where they should be.


Gooped up! Can't hardly tell from the photo, but there is gasket maker a all over the place.


Flipped over and bolted up.


Flipped back over and done for the night.
__________________
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)

DisTech screwed with this post 05-15-2010 at 08:25 AM
DisTech is offline   Reply With Quote
Old 05-12-2010, 09:04 AM   #158
procycle
Beastly Adventurer
 
procycle's Avatar
 
Joined: Jun 2007
Location: Center of the DR650 universe
Oddometer: 2,216
Quote:
Originally Posted by DisTech
I went up to 45 minutes and the other bearing was still tight in place. Oh well, 50% success with the oven!

Good thing for the backup pilot bearing puller. After a lot of farting around, filing the jaws so they would not just pullout without the bearing, success!
For the bearings that don't fall out on their own I just make sure I have a wooden block handy. Just hold the case upside down and smack it against the wooden block. That will pop out all but the most stubborn bearings.
__________________
Clarke's second law of Egodynamics: "For every expert, there is an equal and opposite expert." - Jasper Fforde
www.procycle.us - Everything for your DR650 and lots of other great stuff!
DR900 Big Bore Stroker buildup
TurboDiesel Corvette - go to the end to start at the beginning
procycle is offline   Reply With Quote
Old 05-12-2010, 10:18 AM   #159
zipper2680
couch traveller
 
zipper2680's Avatar
 
Joined: May 2009
Location: Portugal
Oddometer: 67
Looks good...keep it rolling!!
__________________
94 XR600R
2000 Transalp 650
zipper2680 is offline   Reply With Quote
Old 05-12-2010, 11:33 PM   #160
DisTech OP
Studly Adventurer
 
DisTech's Avatar
 
Joined: Sep 2008
Location: Seattle
Oddometer: 616
94 DR455 - Case reassembly, right side.

Keeping it rolling!

Cam chain sprocket and key.


Primary drive and oil pump drive.


Took me a minute to realize the gear shift stopper can only go on one way, the pins are off center from the center bolt hole.


Here is the new beastly 8mm Kientech gearshift stopper bolt.


Screws and bolt loctited in place. Doh! Blindly following the manual, they don't tell you to put in the tensioner that's under the gearshift stopper.


Got it in anyway.


Gearshift shaft and kick start shaft in place.


Oil pump driven gear.


Kick start driven(?) gear is also not mentioned in the manual under reassembly. Glad I didn't torque the clutch in place and then notice it.


Primary driven gear.


Clutch in place.


Close the right side up tomorrow.

The other bike it progressing as well. De-greased the 250 case (that I pulled all the bearings out of) at work yesterday and took it to Seattle Powder Coating for sand blast and pc.
__________________
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)

DisTech screwed with this post 05-15-2010 at 08:26 AM
DisTech is offline   Reply With Quote
Old 05-14-2010, 09:41 PM   #161
DisTech OP
Studly Adventurer
 
DisTech's Avatar
 
Joined: Sep 2008
Location: Seattle
Oddometer: 616
94 DR455 - Closing the bottom.

New seals and gaskets.


Right side closed.


Dirt model stator right, being replaced with the left street model stator.


If you are following the manual you will notice that I am not supposed to put the magneto cover on yet.


Too late!
__________________
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)

DisTech screwed with this post 05-15-2010 at 08:27 AM
DisTech is offline   Reply With Quote
Old 05-14-2010, 11:51 PM   #162
DisTech OP
Studly Adventurer
 
DisTech's Avatar
 
Joined: Sep 2008
Location: Seattle
Oddometer: 616
94 DR455 - Topend reassembly.

Jesse provides everything you need. DRZ400 piston, sleeve and rings. DR350 piston has an arrow on it that is supposed to point toward the exhaust. The DRZ400 piston just has an indented dot. I had to download the DRZ400 manual for that and how the rings go in.


I was expecting those circlips to be a PITA, but they weren't that bad.


The cylinder from Jesse has an aluminum sleeve and weights 3lbs as apposed to the stock steel 5lb model. Saved 2lbs, w00t!

Compressing the rings was a little tricky, but also not to bad.


Bigger valves!


It's looking motor'esq!
__________________
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)

DisTech screwed with this post 05-15-2010 at 08:30 AM
DisTech is offline   Reply With Quote
Old 05-15-2010, 02:22 AM   #163
andrew x
Adventurer
 
Joined: Dec 2008
Location: Czech
Oddometer: 24
nice photos, thanks
andrew x is offline   Reply With Quote
Old 05-15-2010, 08:49 PM   #164
DisTech OP
Studly Adventurer
 
DisTech's Avatar
 
Joined: Sep 2008
Location: Seattle
Oddometer: 616
94 DR455 - Closing topend.

Megacycle reground rockers.


Megacycle cam, R/D springs, titanium tops, RedLine lube, Suzuki molly paste and red silicone gasket maker!


Put on the cam chain tensioner and oil pipe, wait til tomorrow to torque the rocker cover bolts.
__________________
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)
DisTech is offline   Reply With Quote
Old 05-15-2010, 08:51 PM   #165
DisTech OP
Studly Adventurer
 
DisTech's Avatar
 
Joined: Sep 2008
Location: Seattle
Oddometer: 616
Quote:
Originally Posted by andrew x
nice photos, thanks
Thanks andrew x.
__________________
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)
DisTech is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 03:55 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014