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Gregs 2002 FS650 project / rebuild.

These two gears in the picture below, are they purely for the electric start system? Mines no starter motor so can I get rid of these two? Think. One is just and idler the other the sprage?
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Yes you can remove them both they are only for the E start (the smaller one is the torque limiter and the larger is the freewheel)
Keep them in case you ever want to re fit the E start
 
I doubt I'll ever sell this like it or not [emoji23]

I'll remove the gears, probably best to remove the bearings too.

I think whilst the engine is so accessible it maybe worth taking the motor out and giving it a rebuild?

Any one give a rough cost total in parts for a build?

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The head makes me think this hadn't been done for a long time
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Found this on the manual decomp too. Guessing I'll remove that to.
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The engines out. Used some cheap fairy lights I had in the cupboard to see in my garage. Think it looks a bit dodgy. It did the job though.
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The engine has been split. I'm amazed how good the inside looks! Pretty clean. All the bearings feel smooth. I'm still going to change them all and start a fresh. It's looking more and more like I'm just going to refurbish the entire bike. Now the engines out I may aswell sort the frame. I'll have to take the forks out, may aswell get them looked at, it's just keeps going. Should be awesome when it's done though.
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Bit of an update.

The cases are now split and stripped all bearings are now out and awaiting replacement.

I gently heated the whole casing then rapidly cooled each bearing. I had my big hammer but wasn't required at all. Came out easy enough.

I must say Mrs Greg wasn't happy at all my engine was in the oven, she thought I'd made a start on dinner. Well until she opened it to see what it was [emoji23]
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The engine is now fully striped down awaiting cleaning and the new parts to arrive.

Today I've cracked on with the frame ready for powder coating. Feel like I've made progress today. Either that or turned a bike into lots of bags of bits.
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The frame has been dropped off at the powdercoaters and should be ready to start rebuilding soon.

I almost have a full set of bearings for the engine, just waiting on the mains.

I also have both sets of wheel bearings, head stock bearings and swing arm bearings all waiting to go back in. I have all the Gaskets to rebuild.

Just waiting now.

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The frames back! Looks like new although I think I may have gone a shade light.

The guy at the powdercoaters asked if there was anything else I wanted in same colours whilst he was doing my frame.

Do this kinda happened. [emoji23]

Should brighten it up a bit [emoji23]
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Pretty!

you'll need to get the paint out of the inside of the rocker end cap holes. its not that you can't grind it down, more that the paint will bind and make the caps stick etc.

these covers often get out of flat so use a surface plate and you shopuld end up with an excellent contact face.

Taffy
 
Yeah I think that's going to have to happen. I wasn't expecting the guy to have coated those bits. Worried about any bits making their way around the engine now

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Not done a bad job of the frame though, I took the frame into the house and put helitape on the bottom bits and some of the high wear regions.

Just waiting for a tub of grease to arrive then I'll start putting her back Together.
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Been progressing slowly. Starting to put bits back on the frame.
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The bars are on and the rear brake bled and good to go. I've decided to try going for dual levers on the front of the bars instead of the thumb brake. Used the hayes stroker. I was surprised how much power it has. The front brakes on but not connected up I'll get some fluid in soon so can a absorb any moisture in the lines. I'll give it a good bleed before it makes it first ride.
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gregfreefaller said:
The bars are on and the rear brake bled and good to go. I've decided to try going for dual levers on the front of the bars instead of the thumb brake. Used the hayes stroker. I was surprised how much power it has. The front brakes on but not connected up I'll get some fluid in soon so can a absorb any moisture in the lines. I'll give it a good bleed before it makes it first ride.
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Click to expand...

Can you expand a bit on what you mean a dual levers and not a thumb brake? Do you want more oil capacity in your motor? 2 or 3 liters? Wet ignition gives u 2. Add external spin on filter and u get around 3 L.
 
Certainly. I used to wear the thick chunky sole supermoto boots a d found I couldn't really feel the back brake.

So I decided to fit a thumb brake on the left bar. I used a reversed ducati 916 master cylinder and trimmed the lever down.

I have been doing a bit more research and spotted a system where you have the rear brake on the left hand but on the same side of the bar as the clutch.

Similar to this set up
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