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22-6-2016 M2 rod knock, Uly topend overhaul thrott
28-7-2016 - 22-6-2016 M2 rod knock, Uly topend overhaul throttle shaft replacement in detail , Uly crash damage, XB gearbox start
customer justg bought a M2 nice bike... but that knock ? is that normal ? well after hearing this... rod knock... no not really normal..we took the engine out, and started disasembly to look at the damage
big end bearing is out.. and the debris has scarred the cylinders/ pistons
cylinder liners rear cylinder are loose, i think we will go for the Xb cylinder option, with the bigger cooling fins , bore is the same
5e gear bearing is half way out, as the seal has been leaking already ( belt was also way to tight )
oil pomp gear , remarkeble the oil pump it self was not hurt ..
crank pressed out , and packed to go the the machine shop
valve are not that bad , can do with a cleaning and re grind.. but not really much play in theme
Uly top end overhaul, time to put the headers on.. i will replace these corroded exhaust lock rings
with some fresh ones the header will stay on longer
headers back on
now the fix the original problem... the broken throttle shaft
first tps sensor off
and take the nylon bushings out
you can turn the trottle around and nip the end off the screw off ( lock screw )
you can try to unscrew theze throttle shaft screws but most likely they will not come out, drilling the head off to recover the plate
carefull , not to hard ,
with the head drilled off you can pull out the plate and last piece off the shaft
the throttle cam... with the other end off the broke off shaft
our new throttle shaft, whitch we make.. made ready for bought model TPS sensors models
lyning up the bits and pieces
fist on is the c-clip on the tps sensor side
little silicone grease and nylon bushing back in
new shaft put in and slide the throttle plate in after cleaning , line it up in closed position
little drop off red loctite on the screws ( we provided enough in the kit )
and tighten the throttle plate
vilt ring on the throttle cam side
and nylon return spring guide
hook the cable cam on the spring and twist the spring lyning up with the slot
and put the lock nut on, thighen and check the spring runs free and you don't pinch it
and test the working, need to run smooth, open and closed
now for the tps sensor... check what model tps sensor you have , this is old model ( 1999-2006 )
and put the pin in the hole so this will work with your tps sensor
put the tps sensor on , turned like this
and rotate it so you fasten the screws
a litle neverseas on the idle adjuster
about ready to go back on the bike
top mount and coil bracket on the heads
line out the coil bracket as this doubles as the manifold support
and trow away the corroded screws
manifold in and injector wires back on
plug an cables the easy way ;-) ( with engine rotated
and don't forget the pcv valves before you rotate the engine back up
engine up and v-brace back on
mnnn yes need to fix this to broken off cover screw
and need to put a shifter pivot bushing in here
cover off to have a look at the drilled off screw
sutch a end stickong out... lets try with a stud extracter
ok.. that did not help , but broke clean off , but nice starting point to dril the screw out
will take the clutch and chain off
and after some drilling... retapping the threads
works :-)
clutch basket back on , prelube the hub needle bearing
out , mainshaft retaining ring
primairy back on, and new gasket
cover back on and tq to specs, circle out pattern
fresh oil in and clutch mechanism back on
original spacer did fit the non stock shift lever
and checking the primairy chain tension
noop i will not mount this one back on...
customer provided with a almost like new one ... better
rear straps on
yes a other one i need to dril out... lucky me :-)
cables connected, the throttle was sticking on the bar end plug ... don't like when throttles stick
check if the oil pressure light burns
this one would make oil pressure after a few turns off the engine , nice
new set tps
and fist heat cycle...30 sec... runs not great, but this will get better soon.. the fresh bores and running in lube need to get the frist rough edges off
so 30 seconds... smoking from the mounting lube used... cool down for next heat
my college, started the Xb gearbox problem.
stripping the engine out the bike
Uly crahs repair
bike did fall on the right side, brake lever, handle bar ect...
removing the wind guards... heat up the screws there in with loctite and you will damage the heads... trust me
right side switch off
hardly to see from the out side , but brake lever broke , this one was sticking, but we see these allot and not sticking !! only way to tell there pointing down a little
left side all the stuff off the bend handle bar
heated grips left side is screwed on with 2 screws
8mm.. cluch lever bracket off
and old bend handle bar off
nice new handle bar for Uly comes with the heated grip holes predrilled
new brake lever on , with grease
old mirror off
new one in
new bar end plug hammered in, these can be a reall pain to mount
my collegue , has take the engine out, to morrow strip down to look for the 2e gear ( is not working