This trick works well for me, and you can watch the video I found below to find out how it works. If the Nikasil coating is damaged, the cylinder may need replating. Valve adjustment – 1 hour long and is a maintenance item that every owner should learn how to do properly. Simply grab the con rod and push and pull it while feeling for any movement. Screwing them back in will also help you to remember where each bolt goes when you come to put the engine back in. The piston will now lift off, and you will see a needle roller bearing (the small end bearing) that you can remove from the con rod. An hour before you start stripping your engine, take your new main bearings and place them in the freezer. Removing the nut will require your clutch basket holding tool, these tools grip the clutch basket to stop it turning while you loosen the nut. I'd love to be able to keep driving my car while I work on a new bottom end, so I'm thinking I'll buy an M10 block and build it up from there, then swap it out with my old one. You will need the expertise of a mechanic to tell you if it is indeed time for an With a few tools and a little knowledge, a 2-stroke top end rebuild can be done by any rider in a matter of hours. If you're rebuilding the bottom end I'll assume that you will also be replacing the piston, so you will require all of the above tools, plus: All of the special tools are essential, and you will likely cause damage to the engine if you try to do the job without them. In this 3 part video we'll be demonstrating how to completely rebuild the bottom end on a modern day 2 stroke motorcycle or ATV engine. No Restock Fees. Installing a new crankshaft assembly and crank bearings is all part of this process and using the right tools is going to make this process quick and easy. You can remove just one piston clip, and push the gudgeon pin from the opposite side. To find the correct size piston, you will need to measure the cylinder with a bore gauge. I will probably reuse my rods and just shot peen them if possible for added strength. When you have the correct measurement, insert the piston ring into the cylinder, and use the feeler gauge to check the gap. Never try to tap it through with a hammer, as this can knock it out of alignment, causing it to become tight in the bearings. The Bottom End is Noisy - A worn clutch basket which has started to rattle, damaged or stuck bearings, a worn bushing and needle bearing between the clutch basket and primary shaft, or gears which are improperly lubricated may all contribute to bottom end noise. When the piston is installed, check that both piston clips are correctly seated into their grooves, and that the gap isn't lined up with the dimples. The Tusk case splitter will make the job a breeze, and it comes with full instructions, or you can find plenty of helpful videos online. With the teardown and machine shop episodes out of the way, we can now start rebuilding our block. Additionally, a considerable amount of money can be saved by taking on the work yourself versus tasking a shop to perform the work. The first thing to fit is the new base gasket, and you can coat the gasket in grease to help it seal, and to help it come off the next time you remove the cylinder. If you buy the tusk crank puller, you will find some great instructional videos online, and it comes with full instructions to help you out. You can simply move the case splitter to the other side to push it out. Removing all dirt and grit lowers the risk of any of it falling into your engine, where it could cause damage when the engine is started. To do this you will need a feeler gauge, and a small needle file. Idk … When you remove the casing on the right side of the engine, the first thing to remove is the crank gear. These valves are located in the exhaust port, and they can get very dirty, which causes them to stick. I plan to replace my crank with a complete crank/rod setup from hot rods. Rebuilding the bottom end of your engine, whether two or four-stroke, can be a fun and rewarding job. Hi Adam, you’ll need to take the transmission out. All dirt bike bottom ends vary, so this section will just include the most important tips and helpful information. You can then remove the clutch plates and clutch basket. If you feel and resistance, stop and check that the ring is located correctly. A better way to remove old seals is to use a very small drill to make a hole in the seal, and then screw a self tapping screw into it. I have a 96 gtx with the 787 engine. If the screwdriver catches the surface it can cause damage to the aluminium, which may stop the new seal working, or even damage it as soon as it's installed. I'm sure that led to some issues with the bottom end. When it comes time to split the cases, you'll find that they are very tightly fused together, and you will most definitely need a case splitter to avoid damaging the cases. To install your new crank you will need to use your crank puller to pull it through the bearings. Flywheel puller (link to flywheel puller on Amazon), Plastic scraper (an old credit card will work), Large sockets and spanners, up to 28 mm should cover all dirt bikes. Simply put the bike in gear to lock the clutch and they'll come out easily. (pistons are numbered not color coded) When you rebuild the motor , your machinist will attempt .0001" accuracy and get real close, Something that was impossible in the factory (gang jobs). Its not terribly hard to do if you have the right tools, have an FSM handy, and know a good machine shop. This is part 1 of this 3 part engine rebuild series from Rocky Mountain ATV/MC. I'm guessing it came apart some time ago. I’m wondering what the go is with the transmission components when splitting the cases to replace the crank? When it comes time for an engine rebuild, many riders pass their dirt bike over to their local repair shop to have the work done. The Tusk crank puller is essential for installing the new crank. Are there any things to watch out for with the transmission during this process such as components coming apart that are tricky to put back together? Bottom end rebuilds will take a lot longer, but they can also be done by anybody with a couple of days to spare. This part can wear out, and over time becomes oval. You may want your engine to perform like, or better than, the day it rolled o… The seals are very easy to install by tapping them into place with a socket and a hammer, but be careful not to tap them in too far. When the crank gear is off, check to see if there are any other gears that can be removed with this method. In this episode Chris shows you how to rebuild the bottom end of our block using pistons from MAHLE Motorsports, and a crank from Eagle Specialty Products. An hour before you started stripping the engine, I told you to put your new main bearings into the freezer. Now place the head gasket onto the cylinder, this gasket doesn't require any grease or sealing compound. When I do my engine, I will either do a cyclex motor, or do a bare check on my bottom end and put the money into the top in the form of a hotter cam and some porting. If you discover play, but decide not to replace the crank, you risk a big end failure, which can totally destroy the engine, so don't risk it. A bottom end rebuild will obviously require engine removal, but many people leave the engine in while carrying out a top end rebuild. Get your 2020 MX girls calendar at Amazon by clicking here, Motocross arm pump: 10 steps to get rid of arm pump fast, Motocross Fitness: How to train for MX racing, Dirt bike riding tips for beginners: 11 top riding tips to develop skill fast, Dirt bike wheelie: Wheelie like a pro with these top tips, Dirt Bike Maintenance: 12 tips to keep your machine in tip top condition, 2-stroke top end and bottom end rebuild tips for beginners. These will be very tight, and can be a pain to undo when the engine is freely moving around your bench. Check out some awesome accessories for your dirt bike HERE. Start by draining the water from the engine and radiators, by removing the bleed screw on the water pump. I have a once over set of pistons I won from cyclex in my basement that I will also bore for. I took it to a dealer and they told me that the bottom end needs rebuilt. The reason for setting the gap is to allow room for expansion, so that the two ring ends do not hit one another and break. When the main nut is removed you will need to use the flywheel puller to release the flywheel from the tapered shaft. In this video we cover the beginning engine tear down such as removing the flywheel and stator assembly. Before you start work, it's important to thoroughly wash your dirt bike. Unfortunately, this can wind up costing an arm and a leg, and it really isn't necessary. Complete Top and Bottom End Engine Rebuild Kit - Four Stroke The side that has any lettering on will face up, so that the tapered angle faces down. Keep all of your clutch plates in order as you remove them from the basket. Everything from the clutch, to the cooling system, to bottom end components. Tighten every nut and bolt back up to the specified torque, and remember to clean your contact surfaces so that the casing seals against the gaskets. Every manufacturer will recommend a different ring gap, so you will need to look up the measurement for your particular engine; or refer to the replacement piston manufacturers recommendation. If you are going to rebuild the bottom end, you might as well do the whole engine. Keep loose nuts and bolts in a jar, and screw them back into the frame to keep them safe wherever possible. Time to Rebuild (Part 1)? A Beginner's Guide to Engine Rebuilding: At a certain time in your life, especially if you are a car guy or gal, you may find the need to rebuild an engine, and there are many reasons why you might discover this. If the ring is installed the wrong way up, it will feel tight, and it will stick in the piston's ring groove, so check that it moves freely before proceeding. Don't scrape it off with a screwdriver as this will damage the soft aluminium surface, use the old plastic credit card mentioned in the tools section. For bottom end rebuilds, it's also worth removing your clutch cover and loosening the spring bolts, as doing this with the engine out can be difficult. Cash Back Rewards Program. ⚡ TRENDING NOW ⚡ CRUZTOOLS DMX2 FENDER MOUNT TOOL KIT │ CLICK HERE, In Beginners, Dirt bikes, maintainance by darrellsmithDecember 23, 20182 Comments. You should also check the top of the con rod where the small end bearing goes, known as the rod small end. I use the Tusk crank puller (pictured below) and a Tusk case splitter, they work great and you can buy them as a package on Amazon as I did here > Tusk Tools. That being said, it took me like 3 months to build my engine, but it was my first time. Click here to read more about me. Do this until the gap is correct, and be very careful not to file off too much of the ring. 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