My '03 FC550 Rebuild (lots of pics)

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looks like you have your work cut out for you. No turning back now. lol keep track of you coast in parts for us would you please? Good luck, I love thease kind of posts.
 
Taffy said:
MX flywheel and stator?

that cylinder wants to be honed within an inch of it's life.

i'd have a new piston complete.

regards

Taffy
Click to expand...

Could be Taffy its a FC550 engine. Whats the difference between the MX flywheel/stator and the 'normal' one?
If I have my new piston I'm gonna send the piston and the cilinder to powerseal here in Holland for a new nicasil layer.

looks like you have your work cut out for you. No turning back now. lol keep track of you coast in parts for us would you please? Good luck, I love thease kind of posts.
Click to expand...

Yep it's a lot of work and money, but then I will have a better then new engine :)
Will keep you up with parts in prices.
 
i use langcourt here in the UK and they are £122 delivered in a huge foam filled box. they also measure for ovality and diameter. they junk 1 in 4/5 linars. just to let you know.

regards

Taffy
 
Ok, I want to remove my counter balancer, can I just pull the complete balancer off my crankshaft, let my crank rebalance and then its ok?
And what about this gear:
CB.jpg


It should just stay there do nothing?

Thanks!
 
just leave it. it was the powerr to your c/b. lineaweaver machined his down to a stump and i believe the phot used to sit in his gallery.

regards

Taffy
 
Taffy said:
just leave it. it was the powerr to your c/b. lineaweaver machined his down to a stump and i believe the phot used to sit in his gallery.

regards

Taffy
Click to expand...

I spotted the photo, thanks.
Have you found out what piston is best for me to use Taffy?
I will email you in a minute about the things I need for the rebuild.
 
not really! you didn't finish telling me your squish, at least, i took it that you were on about the minimum reather than a true measurement?

if you have just 2mm clearance then it would be just as well to get the longer rod (by 1mm) and have a flat top.

if you had 3mm i would defo get the concave OEM 2006 piston and have a tiny amount whipped off the rim/outside edge.

regards

Taffy
 
Taffy said:
not really! you didn't finish telling me your squish, at least, i took it that you were on about the minimum reather than a true measurement?

if you have just 2mm clearance then it would be just as well to get the longer rod (by 1mm) and have a flat top.

if you had 3mm i would defo get the concave OEM 2006 piston and have a tiny amount whipped off the rim/outside edge.

regards

Taffy
Click to expand...

No Taffy it was a real measurement, my squish is 2,005mm (measured twice, same result).
So I can go with the 100mm HC piston then?
Just emailed you btw
 
so if the doc's tuning section is right, you have the shorter 123mm rod in there? right? if you could still get the older rod from '01 & '02 that would get rid of that 1mm extra gap. if you can afford it, and i haven't seen one for months, get the '06 piston and have 2 of the 3 mm squish rim machined off. infact you can machine off to perfection when you have too much material.

regards

Taffy
 
Taffy said:
so if the doc's tuning section is right, you have the shorter 123mm rod in there? right? if you could still get the older rod from '01 & '02 that would get rid of that 1mm extra gap. if you can afford it, and i haven't seen one for months, get the '06 piston and have 2 of the 3 mm squish rim machined off. infact you can machine off to perfection when you have too much material.

regards

Taffy
Click to expand...

Dont know which Rod i have, are there any marks on the rod to see what type it is?-->Just checked, the side of my rod say's 156.. Is that of any help?

I want to go for the '01 and '02 rod kit with the '06 piston, but I read in the other thread this con-rod is very hard to find? Can you still get it Taffy or should i call brouwer motors if they can order it?
 
i'll ask myself tomorrow and get a price. you don't need a 124mm rod AND the piston. it's either or.

either get the early 124mm rod and a flat topped piston
or keep your rod and go straight to the '06 piston. the '06 piston has a rim like a cigarette ashtray.

regards

Taffy
 
Taffy said:
i'll ask myself tomorrow and get a price. you don't need a 124mm rod AND the piston. it's either or.

either get the early 124mm rod and a flat topped piston
or keep your rod and go straight to the '06 piston. the '06 piston has a rim like a cigarette ashtray.

regards

Taffy
Click to expand...

Well my rod needs to be replaced anyway (big end play of about 1+mm).
 
Little update, left crank bearing is pressed out, engine cases are clean now :)

1_001.jpg

1_002.jpg

1_003.jpg

1_004.jpg


Parts off the engine:
1_005.jpg


More parts, rest off the parts are under the blanket
1_007.jpg
 
Extra update, my new bearings are here (exept crank bearings since they are special order)

03042009007_G.jpg

03042009006_G.jpg
 
Bluto said:
Sorry to reopen this topic,but did you finish the engine?
Click to expand...

Yes I did, will try to find extra pics on my computer.
Ran it now for 1 supermoto season (about 25 to 30 hours) and still running :)
This winter I am rebuilding my '02 engine as a spare.
 

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