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Just got bike - Nightmare in 30 minutes! HELP please

Joined Feb 2007
3 Posts | 0+
UK
Hi all,

I'm a complete newbie with these machines, but I bought a 1996 600 yesterday just to have some fun on, after hearing it running and it was sold to me by a friend. I race Drag bikes, hence the reason for buying an older model, as most of my cash goes on the racing bike(s).

Anyway, I got it home in a van and decided to give it a full service before starting it just in case it had been neglected. I know the engine has been re-built by a reputable ex-racer, who I have met and this really convinced me that it would be a good buy.

The first thing I did after removing the plastic and tank was to remove the flywheel cover (black plastic) - and out came the oil, complete with lumps of metal (resembling pieces of piston ring, for want of a better description) and what was obviously ground alloy particals in the (black) oil forming a paste. Nightmare! I cannot detect any play in the flywheel and everything spins round freely when using the kick starter to turn the engine, but something has obviously broken up and the oil should not be there.

Any ideas? I'm going to get a flywheel puller and holder at the weekend from the guy who re-built it, but I woud like to have an idea what the problem is and the remedial action necessary before I see him. I'm sure my friend had no idea that the problem existed.......

Not a good start with what I thought was going to be a great experience! :(

Cheers

Tony
 
it could be left over chunks from before the rebuild. definately not a good start tho.
 
could be a screw on the stator came loose,on my 98 when I loosend the bottom stator screw I had oil leaking into that area.When I split the cases a few years ago we noticed the screw had loosend and luckily had not yet fallen out.It was however just starting to scrape the flywheel.Good save!
 
TonyS said:
Hi all,

I'm a complete newbie with these machines, but I bought a 1996 600 yesterday just to have some fun on, after hearing it running and it was sold to me by a friend. I race Drag bikes, hence the reason for buying an older model, as most of my cash goes on the racing bike(s).

Anyway, I got it home in a van and decided to give it a full service before starting it just in case it had been neglected. I know the engine has been re-built by a reputable ex-racer, who I have met and this really convinced me that it would be a good buy.

The first thing I did after removing the plastic and tank was to remove the flywheel cover (black plastic) - and out came the oil, complete with lumps of metal (resembling pieces of piston ring, for want of a better description) and what was obviously ground alloy particals in the (black) oil forming a paste. Nightmare! I cannot detect any play in the flywheel and everything spins round freely when using the kick starter to turn the engine, but something has obviously broken up and the oil should not be there.

Any ideas? I'm going to get a flywheel puller and holder at the weekend from the guy who re-built it, but I woud like to have an idea what the problem is and the remedial action necessary before I see him. I'm sure my friend had no idea that the problem existed.......

Not a good start with what I thought was going to be a great experience! :(

Cheers

Tony

Take it back to the guy you bought it from and get your money back!

Regards,

Joe
 
my guess is that the oil is coming from a bad crank seal and perhaps made worse by a plugged vent tube on top of the engine. as to the metal, prolly the flywheel is delaminating. the stator screws do indeed loosen up if not properly tightened/ sealed.

ned
 
Got the flywheel off. one of the stator screws had snapped, due to this the other two had wobbled about sufficiently to elongate the screw holes such that they simply fell out with the stator! theholes must go right through into the crankcase, hence the oil getting into the flywheel area.

Has anyone successfully HeliCoiled these holes or is it a new crankcase?

Tony
 
If you helicoil, be sure to use sealant on the OD of the coil. You will need to wait a day for the sealant to dry before inserting the new screws. Otherwise, they will be "loctited" in place and possible pull out the helicoil in the next service.

MarkT
 
better to drill and re tap if ya can. but heli coils are damn strong, I have one holding a head bolt in my mazda mx6. Like mark said you'll definately need to seal it tho.
 

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