Ok well it's time to rebuild my 06 510. It has a tad over 12,000 miles and never let me down. I figured I would give her a complete rebuild including a 530 kit. I took all the pics to use as a reference for assembly but maybe it will help someone here.
Do not pull on the oil line it is held in by the cam holders
Remove the cam holders. Do not mix them up but they are numbered 1-4
Set them aside for now.
Remove the 4 head nuts AND washers. You will need to turn the engine upside down to get the washers out.
Here is my 12k cylinder and piston. Piston had no blowby and the walls were near perfect still. I have no doubt it could gave gone another 8-10k. Except the lower rod bearings are a known weak point
No 530 yet. I'm sending the head off for inspection, the crank to have the counterballancer gear pulled. And installed on my new RR crank. Since they don't have a counterballancer.
And since I'm waiting I'm powdercoating the cases that matte black like my covers.
I'm also rebuilding a 04 450. The lower rod bearing went on that motor blowing the cylinder. So I'm giving my buddy my 510 cylinder and crank. But he is putting a new rod in my old crank.
Don't forget to put the crank spacer back on the STATOR side!
Also wise to inspect the oil pump and the transmission shift drum. They can wear out over time. Especially check the oil pump, it's a vital component to your engine.
When pulling out the transmission, start by removing the shift forks and their shafts. you can then CAREFULLY pull out the two trans shaft assemblies together, same time. Be careful not to lose any gears as some of the parts are loose and can slide off. Inspect transmission for unusual wear and damage. If it's good to reuse as-is, then wrap up the two shafts together as one assembly. Use plastic shrink wrap and they'll be assembled, protected and nothing will slide off.
This is the crank spacer. When you split the case it may be stuck to the bearing or may be sitting on the crank by the ballancer like in the second pic. That's a 04 450 that blew. I'm rebuilding that one too.
I will be doing a very detailed step by step with pics on assembly. I sent my head off for inspection and my new crank to have the counter ballancer gear installed. Will be mid April
What else is worth my change when I put that 530cc kit attached, bike is driven about 5500 km and on the street, all maintenance done on time, etc.:hmmm:
Stock parts etc...
I was also advised to check my oil pump. Take the big gear off and spin the pump and make sure it spins freely. Mine sticks a tad in one spot so I'm replacing it.
I thought I should ad this as I discovered one missing from my motor yesterday. And at 15 bucks apiece, possible assembly without it, so I thought I would post it up. With the cases split the shafts holding the transmission fork can slid out causing the nub that sits in the shift drum to come out. This is a easy part to loose.
Ok to remove the counter ballancer bearing. You will need a pilot bearing puller. I bought this snap one one today. I will need to modify it but I worked ok. You must make sure the tool is centered on the bearing and the feet are even and flat on the case.
Just doing some odds and ends until the rest of the bearings show up. Notice the yellow stuff? It's a special type of non drying epoxy primer. I'm using it to prevent any corrosion caused by disimaliar metals. (steel bolt, aluminum case) I like how the fresh powdercoating came out.
Turned out amazing. Who'd you go to for the powdercoating?
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