Posted: Tue May 01, 2007 7:33 pm
Well, let me first by saying thanks to those that sent me a few parts. It was a big help as I was a bit short on parts in the end there. Jimbo, timbo, brad, wistech, 27, ACEwrench, and Mike, much appreciated.
So, now onto the build. This will be the LAST time I do a build from scratch. This quad was not a roller and did not have a full motor when i started it. I have collect a lot of parts of the years and thought I would put them to good use. The motor was the hardest part. I got the case in a trade for labor as it wasn't good any more. It was an old fx400 case that had the bearing go and the guy bought a new 03 case as a replacement. So, I had the bearing sleeved and went ahead and converted it over to a hydrolic clutch case. Couple hundred dollars later after I had replaced all the bearings and was ready to go. Got the big crank in from Timbo and went to work on it.
So, how did the motor build go? oof Started April 19th and my dune trip was April 25th.
Wednesday April 19th:
Recieved the crank in the mail and the piston, but no sleeve
Case is at the shop getting the very small roller bearings removed.
Thursday April 20th:
Went to go get the case and it was damaged from a bearing removal. Guy was resleaving the small roller bearing and just didn't finish. I could have cried.
Received the rest of Tim's shipment and was told that the sleeve in the box was defective. I looked at it and it had a chunk of metal missing from manufacturing. EEK! It was in the water jacket area but it could be usable if needed. Tim talked with Doug and he was sending me out some new sleeves he had left over over night. woot!!
Friday April 21st.
Got the case back today. Very nice work so I got it cleaned up and bearings installed.
Got sleeve in the mail today. It was used, very used, and too tight to to work with the new CP. EEK!! Talked with Tim and we decided to go with the defective sleeve. I epoxied up the defect and let it cure.
Installed the crank and tested side play. Was a bit too big so I shimmed it out. Reinstalled the crank and it was a bit too tight, so I had to pull the crank again. One of the small bolts decided to seize on its removal from the cartridge plate. Spent a good hour or two removeing it and rethreading its hole. So I get the crank installed and its working find. I get the plate all mounted and the oil pump seems to be turning fine. We are behind at this point but no point in staying up till all hours with a few days left.
Saturday April 21st:
I go to install the tranny and it slides right in. But I decide to shift the gears a few times just to be sure and it seems to be locking up and not shifting into 3rd or higher. I removed it and reinstalled a couple of times and scratched my head. Then I remembered the last gear on the tranny falling off a few times when moving it around in storage. I yank the tranny back out and sure enough the gear was on backwards. doh! Fixed and its good to go!
I go looking through old valves looking for a best sets and decide on a few keepers. Get them installed and put the head on. Build the rest of the motor and install a set of cams and went to shimming. When I installed the shims I noticed that they were sitting VERY deep in the pockets. As it turned out I couldn't get the exhaust shimmed anything less than .009 without the bucket sitting on the retainer. What happened was I had a full set of old style clips sitting around and grabbed them with the newer Ti retainers. I installed them by hand and it appeared they would "keep" just fine so I installed them. As it happens they do fit and secure just fine but they sit higher on the valve than the newer ones. So, I stared at the motor for an hour. Oh yeah, this was like 1am on Friday night. Decided to pull the head back off and replace the keepers. Got that done and finished up the motor yet again and went to bed at like 3.
So, now onto the build. This will be the LAST time I do a build from scratch. This quad was not a roller and did not have a full motor when i started it. I have collect a lot of parts of the years and thought I would put them to good use. The motor was the hardest part. I got the case in a trade for labor as it wasn't good any more. It was an old fx400 case that had the bearing go and the guy bought a new 03 case as a replacement. So, I had the bearing sleeved and went ahead and converted it over to a hydrolic clutch case. Couple hundred dollars later after I had replaced all the bearings and was ready to go. Got the big crank in from Timbo and went to work on it.
So, how did the motor build go? oof Started April 19th and my dune trip was April 25th.
Wednesday April 19th:
Recieved the crank in the mail and the piston, but no sleeve
Case is at the shop getting the very small roller bearings removed.
Thursday April 20th:
Went to go get the case and it was damaged from a bearing removal. Guy was resleaving the small roller bearing and just didn't finish. I could have cried.
Received the rest of Tim's shipment and was told that the sleeve in the box was defective. I looked at it and it had a chunk of metal missing from manufacturing. EEK! It was in the water jacket area but it could be usable if needed. Tim talked with Doug and he was sending me out some new sleeves he had left over over night. woot!!
Friday April 21st.
Got the case back today. Very nice work so I got it cleaned up and bearings installed.
Got sleeve in the mail today. It was used, very used, and too tight to to work with the new CP. EEK!! Talked with Tim and we decided to go with the defective sleeve. I epoxied up the defect and let it cure.
Installed the crank and tested side play. Was a bit too big so I shimmed it out. Reinstalled the crank and it was a bit too tight, so I had to pull the crank again. One of the small bolts decided to seize on its removal from the cartridge plate. Spent a good hour or two removeing it and rethreading its hole. So I get the crank installed and its working find. I get the plate all mounted and the oil pump seems to be turning fine. We are behind at this point but no point in staying up till all hours with a few days left.
Saturday April 21st:
I go to install the tranny and it slides right in. But I decide to shift the gears a few times just to be sure and it seems to be locking up and not shifting into 3rd or higher. I removed it and reinstalled a couple of times and scratched my head. Then I remembered the last gear on the tranny falling off a few times when moving it around in storage. I yank the tranny back out and sure enough the gear was on backwards. doh! Fixed and its good to go!
I go looking through old valves looking for a best sets and decide on a few keepers. Get them installed and put the head on. Build the rest of the motor and install a set of cams and went to shimming. When I installed the shims I noticed that they were sitting VERY deep in the pockets. As it turned out I couldn't get the exhaust shimmed anything less than .009 without the bucket sitting on the retainer. What happened was I had a full set of old style clips sitting around and grabbed them with the newer Ti retainers. I installed them by hand and it appeared they would "keep" just fine so I installed them. As it happens they do fit and secure just fine but they sit higher on the valve than the newer ones. So, I stared at the motor for an hour. Oh yeah, this was like 1am on Friday night. Decided to pull the head back off and replace the keepers. Got that done and finished up the motor yet again and went to bed at like 3.