Expert Level: 2002 Engine Rebuild
You may remember my Phoenix project from last year, in which I overhauled everything but the engine. Well, as irony loves an opportunity, during my first 800-mile tour of 2018, I *probably* dropped a valve. I haven't had the engine taken out or torn down yet. I know some of you have gotten into the engine plenty of times (lookin' at you, cmg). These are my options:
1. Buy donor bike and swap in a working engine
2. Buy a freestanding engine and swap it in
3. Send it to RC Performance in NC to sort out the failure, then their overbore and porting job
4. Tear down and replace as needed, by myself
Here are the challenges with each:
1. Paying for more than I need for a donor, and buying someone else's problems
2. Very hard to find a freestanding engine (unless I'm not looking in the right places)
3. $4600 for the overbore/porting, plus additional labor and parts for other needed bits
4. Free labor, but I can't weld and remachine anything, or fab any parts. Everything that needs replaced must be identified and purchased, new or used.
Also, a DIY will take me a long time. I've never done an engine. Not too fearful, but I *could* make mistakes.
Right now, I'm leaning toward the DIY, because of the problems for 1-3. So what I need is advice for the following:
1. No one (Facebook groups) has stated clearly how to cradle the engine and pull it out from under the chassis. Some say put wood blocks under it. Others say use a floor jack. I don't want it to fall over. The perfect advice here would include an explicit statement, hopefully with pics.
2. I have most of the basic tools -- wrenches, allens, screwdrivers. I do NOT have any engine specific specialty tool, such as a valve removal tool.
WHAT DO I NEED?
3. Since I am pulling the engine, maybe I should replace parts that could be troublesome later, even if not failed right now.
a. Timing chain (pretty certain on this one, my tensioner was close to the last click when I did valve clearances last year)
b. Oil sump pump (?)
c. Any starter parts (?)
d. Any bearings
e. New clutch wear items (a definite)
f. Clutch basket (? Mine's a B, most failures were A's, correct?)
g. What else...?
The failure was like this. Rattled the day before, hadn't heard it before, thought it might be knocking from high heat (it was 90 deg + that day) and regular unleaded 87 octane. Probably terrible judgement on my part. The bike ran fine for the first 150 miles the next day. I ran it up to 140mph, but it seemed a bit down on power...maybe. Rolled into the next town, then out of town a few miles. Then the rattle became serious, it felt like the clutch slipped just a second, my buddy said a puff of black smoke came out the pipe. I pulled the clutch and rolled onto a stranger's property. Can't remember if it died or I shut it off. Thought I could limp up further onto the property, so I started it again. Still very noisy, but it started and ran. Put it in 1st gear, and it died when I released the clutch. Before you say failed clutch, I can rotate the rear wheel in 1st gear (bike off, raised on rear wheel stand).
So, I'm wondering what I'll find. Tonight I'm going to pull the clutch cover and inspect; then pull the oil pan and inspect (never had it off before). If it's a valve, what are the odds the piston is damaged? The cylinder wall is damaged? The valve head is damaged?
Sorry for the long post, this is going to be a multi-page thread until it's finished. While I will be grateful for any sympathetic posts from my brothers here, I want to be efficient. I'm looking for solid advice and direction. I can't bear the thought of losing this riding season. I've had a running bike for 22 years, (with problems here and there), and we all know it sucks to be rideless in high season.