Sunday, April 22, 2012
S90: Handlebar Mounts
Disassembled the handle bar mounts to get a good look at them so I could order replacement bits as needed.
Sunday, April 1, 2012
S90: Odd Jobs
Decided to stick on all the odds and ends I got from Bike Bandit.
Rusty fork bolts get replaced with shiny new ones. Forgot to order new washers along with it, though.
New gas cap gasket.
New rubber mounts for the gas tank. But the added width pushed back the tank itself, which made it impossible to fit the seat. Going to have to mull that one over a bit...
New square washers inside the headlamp case.
Rusty fork bolts get replaced with shiny new ones. Forgot to order new washers along with it, though.
New gas cap gasket.
New rubber mounts for the gas tank. But the added width pushed back the tank itself, which made it impossible to fit the seat. Going to have to mull that one over a bit...
New square washers inside the headlamp case.
Sunday, March 18, 2012
S90: Gearing Up
Once again the Dremel and the Lisle take down a stuck screw. And with that, I was able to finally pull out the transmission.
Sunday, March 11, 2012
S90: Hallelujah!
Crankcase II is SPLIT!
I thought getting the case apart would be a nightmare, but it really wasn't too bad. Of course, this was Crankcase II, the one I found complete on eBay. Crankcase I may be a different story altogether. But I was pleasantly surprised at how little work it took to get the halves apart, especially after reading stories of having to use a torch or an oven.
I hammered on the shafts as Clymer suggested, but also had to do a little bit of prying with a small flathead, which Clymer suggests against. But really, the halves started to come apart almost immediately, and using the screwdriver around the seam was really just to get the gasket to come apart. About three quarters the way around, as I hammered the screwdriver with the rubber mallet, I heard a "tink, tink, tink, POP!" and it was almost like you were opening something pressurized.
I had a good long poke around the transmission, but ultimately could not yet remove the unit because the screw holding the stopper plate on the shift arm was frozen. The Lisle stripped it, and it'll be tricky to reslot because it's a flat head, and I'll probably have to damage the stopper plate underneath to get it off.
I thought getting the case apart would be a nightmare, but it really wasn't too bad. Of course, this was Crankcase II, the one I found complete on eBay. Crankcase I may be a different story altogether. But I was pleasantly surprised at how little work it took to get the halves apart, especially after reading stories of having to use a torch or an oven.
I hammered on the shafts as Clymer suggested, but also had to do a little bit of prying with a small flathead, which Clymer suggests against. But really, the halves started to come apart almost immediately, and using the screwdriver around the seam was really just to get the gasket to come apart. About three quarters the way around, as I hammered the screwdriver with the rubber mallet, I heard a "tink, tink, tink, POP!" and it was almost like you were opening something pressurized.
I had a good long poke around the transmission, but ultimately could not yet remove the unit because the screw holding the stopper plate on the shift arm was frozen. The Lisle stripped it, and it'll be tricky to reslot because it's a flat head, and I'll probably have to damage the stopper plate underneath to get it off.
Monday, February 27, 2012
S90: Airbox #2 Continued
I'd almost given up on the second airbox, since it seemed impossible to get the stuck screw out without also damaging the tab itself.
But once again, the 4-week break from wrenching proved useful for problem solving. I'd realized I could just clamp the tab down to provide enough support to take the hammering from the impact driver. So I threw two clamps on the tab, then put the clamps themselves into the vice and Presto!
With just a couple whacks the screw freed up, and I turned most of it out by hand. Plus, the tab actually got bent back in the right direction and looks pretty close to where it ought to be now.
But once again, the 4-week break from wrenching proved useful for problem solving. I'd realized I could just clamp the tab down to provide enough support to take the hammering from the impact driver. So I threw two clamps on the tab, then put the clamps themselves into the vice and Presto!
With just a couple whacks the screw freed up, and I turned most of it out by hand. Plus, the tab actually got bent back in the right direction and looks pretty close to where it ought to be now.
S90: My Kindgom for Ring Pliers!
Hadn't been down to the garage in a month (a case of life getting in the way of hobbies), but I think that allowed time for some creative problem solving to percolate around in my brain.
Problem One was the fact that this clutch housing didn't have the little notches in it that allows you to use the basket holder to lock it in place while you remove the locknut. I tried the penny in the gears trick recommended by Clymer. But the first penny just got chomped in two, while the second one seemed to lock the gear, but not the clutch and therefore I still couldn't turn the nut.
But the solution was obvious: just put a very big piece of metal through the con-rod and lock the whole thing up. At first I tried some wrenches, but they were getting bent. Finally this old cheap, but very big screwdriver did the trick.
But after enjoying that success for a few minutes, I was immediately stymied by the fact that I had no ring pliers to get the primary gear off. It seems simple enough to do it without the right tool, but short of cutting it off, I couldn't get the leverage to remove it. Finally decided it was a good excuse to get a new tool and ordered a Lisle snap ring plier from Amazon.
Problem One was the fact that this clutch housing didn't have the little notches in it that allows you to use the basket holder to lock it in place while you remove the locknut. I tried the penny in the gears trick recommended by Clymer. But the first penny just got chomped in two, while the second one seemed to lock the gear, but not the clutch and therefore I still couldn't turn the nut.
But the solution was obvious: just put a very big piece of metal through the con-rod and lock the whole thing up. At first I tried some wrenches, but they were getting bent. Finally this old cheap, but very big screwdriver did the trick.
But after enjoying that success for a few minutes, I was immediately stymied by the fact that I had no ring pliers to get the primary gear off. It seems simple enough to do it without the right tool, but short of cutting it off, I couldn't get the leverage to remove it. Finally decided it was a good excuse to get a new tool and ordered a Lisle snap ring plier from Amazon.
Monday, January 30, 2012
S90: Bottom End #2
Couldn't resist grabbing this complete bottom end, since I knew at the very least I needed clutch parts and a primary driven gear - which individually would have added up to more than I paid for this. Plus, the main benefit is that I can go to town tearing this thing apart purely for the education of it.
As expected, all the screws were frozen, but as usual the Lisle and the Dremel took care of those. But I think the tough part will just be separating the halves, and I'm eager to see how much of an effort that will turn out to be.
If it's impossible to open the crankcase without destroying it, I'd have to consider taking it to a shop to have it done when I do one that really matters.
As expected, all the screws were frozen, but as usual the Lisle and the Dremel took care of those. But I think the tough part will just be separating the halves, and I'm eager to see how much of an effort that will turn out to be.
If it's impossible to open the crankcase without destroying it, I'd have to consider taking it to a shop to have it done when I do one that really matters.
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