A little help? Pics included. 2002 650 melted piston?

GAVBEY · Jul 3, 2014

AHHHH NICE!

I have the 2002 crank so ill have to look into the size of the big end as it seems to be a weak point. is the standard big end copper coated?

yeah keep me updated on the oil relief spring as it would be interesting to see how that pans out

im offshore now so im at the stage of researching and buying parts

GAVBEY · Sep 16, 2014

Just got back to the house. Been fogged offshore for most of the day. Got home to a heap of parts.

Here is the main bearings I'm going to use.

Packing up and sending my crank and barrel to taffy. I'll buy the rest of the bits and Pisces from him to Finnish it all off. Can't wait to get back out there.

GAVBEY · Sep 27, 2014

Not much of an update. Been playing with the oil system and cleaning faces and parts up. Everything looks good.

I drilled my crank feed hole to 3mm instead of 0.75. When I looked through it the hole was actually blocked so the crank was starved of oil.

Here is a pic of it drilled to 3mm

I found a brass washer that would do the job of increasing the relief valve for oil pressure.

And here's it fitted.

Also fitted my modified decompression spring.

I'll be keeping this thread updated basically so I can keep track of what I'm doing.

All comments welcome

bushmechanic · Sep 27, 2014

nice pics gav

might be a good idea to add a bit more force to the ball or measure it somehow ..... I only get 25psi out of my system with 3 lbs on the ball.. i do have an extra 1mm diam oil jet to the main bearing

with the crappy run in oil it was only 20 psi

GAVBEY · Sep 27, 2014

bushmechanic said:
nice pics gav

might be a good idea to add a bit more force to the ball or measure it somehow ..... I only get 25psi out of my system with 3 lbs on the ball.. i do have an extra 1mm diam oil jet to the main bearing

with the crappy run in oil it was only 20 psi

Hi bushiee

Cool I'll try figure out some way of measuring the force with weights or somthing. I'd be happy with 20psi haha. Better than the 8-9psi standard. I suppose when it's all running I could measure the oil pressure and if it needs raised I'll strip it down again. Getting there anyway

spanner · Sep 28, 2014

I am feeding the oil straight from the oil cooler to the crank to save the tourchous route from the other end which will be blocked off at the crankcase parting faces.

Will be putting an oil pressure gauge take off from the upward/forward gallery, all in mind of future a one piece plane bearing crank:spin::spin::spin:

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GAVBEY · Sep 28, 2014

Ah that's a good idea.

Ill give that one a miss though. I crash ALOT and i would end up ripping off the fitting and hose

GAVBEY · Sep 29, 2014

Done some more bits and bobs.
Cleaned up my valves, ported the head, ground some material away for the double valve springs etc

Just waiting for bits to come back.

What's the best way to remove the old mains bearings from the casings??

bushmechanic · Sep 29, 2014

I heat the cases to 150 deg C and tap them on the bench

ball bearings are usually tighter fit might need a drift and a hammer as well

GAVBEY · Sep 30, 2014

bushmechanic said:
I heat the cases to 150 deg C and tap them on the bench

ball bearings are usually tighter fit might need a drift and a hammer as well

Heat in the oven? Or with a light blow torch?

Cheers dude

hacker33 · Sep 30, 2014

2014%5C07%5C17%5Cbikepics-2683547-800.jpg

bushmechanic · Sep 30, 2014

Hi Gav

in an oven I found at the tip

not a nice clean one like Hackers

cheers
Bushie

Hoosaberg · Oct 1, 2014

A hooded barbecue works too if your wife wont let you in the kitchen.

GAVBEY · Oct 5, 2014

Thanks guys.

Well been doing some bits and bobs. Shaved down the head so the double valve springs have plenty room.

I lapped in the valves also. I just used the fine paste though.

Also took out my main bearings and put in my new ones.

As you can see the Iners will be on the crank.

Just waiting for the barrel and piston to come then it's all back together.

Ohhhhh and I also bought a fcr 41 too

Anyway I prefer to show pics.

I need a bung to go in here? It's for the starter motor?

Made some room for the double valves

GAVBEY · Oct 5, 2014

New bearing pressed in

Getting there

GAVBEY · Oct 18, 2014

As you can see the picture above ive gone from ball bearings to roller bearings.

NOWWWW

What endfloat should i look for. manual says between .55 and .65. Reading some threads people have been running a fair bit more with success. Im looking to run about .60,

basically just wondering what everyone normally runs on end float

look forward to any replys.

P.S Can a moderator move change my thread title to GAVBEY'S 02 FS650 BUILD?

Many thanks

Taffy · Oct 18, 2014

whato Gav

I don't think that the title can be changed as the title is the link as well.

you have the weakr 2002 crank so i suggest that you go for the maximum of 0.65mm. you won't need anymore.

regards

Taffy

GAVBEY · Oct 21, 2014

Cheers taffy.

How the hell do I measure it? It seems to be solid! It rotates like a dream but it won't move side to side?

Taffy · Oct 21, 2014

PMd and not repeating it!

LOL!!

taffy

GAVBEY · Nov 11, 2014

Hi guys. So masive update.
Must say thankyou to taffy for all the parts and 24hr service haha.

so first things first then new parts..

double valve springs fitted and also modified my cam chain blade with a longer bolt wich touches the head to stop it bending

pistons

measuring axial play

new barrel and piston in

head on and all timed up

engine back in to the frame

time for a blast

changed the oil. there was aloto of old metal floaring about. changed oil twice after this and now there is none and she runs nice and smooothe

so finally its back on the road and running great.

Thanks you to everyone that helped

Gavin

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