RD'll be back

Got a customizing or restoration project? Post your progress pictures and updates here

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Francis_FR
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Location: Marseille - France

Re: RD'll be back

#16 Post by Francis_FR » Wed Nov 27, 2013 2:44 pm

Hi,

Impossible to put out this kickstarter collar .

Image

As you can see, there is rust Inside it, I used rust remover liquid, I used thermic gun, I even used a puller, nothing, it didn't move a mm after 2 hours on it :-x

I begin to be mad with it, start thinking to cut it
Any idea before I make a "miracle" ? :smt017
Best Regards :smt006
My bikes: Honda CB250K2 1970 / RD350Lc 57V 1985 / RD500Lc 47X 1987 / KTM 250 EXC 2005 /CB600N 2008

theredbarron
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Re: RD'll be back

#17 Post by theredbarron » Wed Nov 27, 2013 4:01 pm

All looking very good Francis, pity about the kickstart boss, maybe a small bearing puller tensioned up and tap the puller with a hammer. If you were in the UK we would remove it for you. Good luck
If only there was more free time.

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Ronnie
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Re: RD'll be back

#18 Post by Ronnie » Wed Nov 27, 2013 8:14 pm

A puller and gentle heat. Might have to be quite hot though before it moves.

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Francis_FR
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Re: RD'll be back

#19 Post by Francis_FR » Sat Nov 30, 2013 3:03 pm

Hi,

There was not a lot of space to set a puller between collar and crankcase cover.

So I went to local supermarket to buy a 8€ made in somewhere small 75mm puller :lol:
No surprise, of course it was too thick, but for that price, it was easy to decide to modified it until it was Ok.
After several try and rework, I finally fixed the pooler, then it just took 4 secondes to extract the collar :grin:
Image

After that, the story can continue, I discovered the clutch.
I pulled the different disk out, and it was the end for today.
As you can see, there was some rust that blocked the collar
Image

On next step, I will start the serious work :smt003
Best Regards :smt006
My bikes: Honda CB250K2 1970 / RD350Lc 57V 1985 / RD500Lc 47X 1987 / KTM 250 EXC 2005 /CB600N 2008

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Ronnie
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Re: RD'll be back

#20 Post by Ronnie » Sat Nov 30, 2013 3:25 pm

Well done!

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jackson.40
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Re: RD'll be back

#21 Post by jackson.40 » Sat Nov 30, 2013 3:40 pm

Top work! :cool:

theredbarron
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Re: RD'll be back

#22 Post by theredbarron » Sun Dec 01, 2013 9:03 am

well done Francis, on re-assembly after cleaning just put a light film of copper grease on and never be stuck again.
If only there was more free time.

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Francis_FR
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Re: RD'll be back

#23 Post by Francis_FR » Sun Dec 01, 2013 4:16 pm

Thanks for the tip.
No work on bike today :???:
Best Regards :smt006
My bikes: Honda CB250K2 1970 / RD350Lc 57V 1985 / RD500Lc 47X 1987 / KTM 250 EXC 2005 /CB600N 2008

vma500
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Re: RD'll be back

#24 Post by vma500 » Mon Dec 02, 2013 2:02 pm

well done

for rusted bolts u can also use COCA COLA ... :shock: yes Francis you read that wright .....c 'est vrai
my bikes :RD500 2X ,RD 350 F2 , RD 350 31K,RD350 4LO,RG500,RG250 WW,RGV250,TZR250 3MA,TZR250 3XV,NS400r,NSr250 mc21,KR1250S,

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Francis_FR
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Re: RD'll be back

#25 Post by Francis_FR » Mon Dec 09, 2013 5:37 pm

Hi !
Here the pictures of the day.

Let's start with clutch
Image

Before removing, do not forget to unlock BOTH primary gear nuts as I did, I use to work on Lc350, here there are two :smt003
Image

Then Kick gear, oil pump gear (engine oil) and primary gears.
The circlip of oil pump gear for transmission is really small, the tool I have does not enter inside..
Image

Here a global pictures of all parts removed today
Image

Well, I have now two standalone 250cc engines...
Coming soon, open the box.

By the way I'm preparing also a special 2 strokes website, with restoration of my 350 and 500.
I prepare a gallery of all 2 strokes I took in pictures in past year through few events.
Be patient :smt016
Best Regards :smt006
My bikes: Honda CB250K2 1970 / RD350Lc 57V 1985 / RD500Lc 47X 1987 / KTM 250 EXC 2005 /CB600N 2008

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Francis_FR
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Re: RD'll be back

#26 Post by Francis_FR » Sat Dec 14, 2013 3:37 pm

Hi,

today was last meter to climb the montain :grin:

First I took the good tool to extract oil gear:
Image

then the oil pump
Image

It's time to extract gear box, slowwwwwwwwwwwwwwly.
Image

Well done
Image

One more time, I had big problem with rusty parts :???:
Image

After few effort to extract the part (and to stay quite)
Image

Et Voilà !!
Image

Now, it's time to check all I can change as engine is open...
Best Regards :smt006
My bikes: Honda CB250K2 1970 / RD350Lc 57V 1985 / RD500Lc 47X 1987 / KTM 250 EXC 2005 /CB600N 2008

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Francis_FR
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Re: RD'll be back

#27 Post by Francis_FR » Tue Dec 23, 2014 4:17 pm

Hello,
Big up for the topic !
After few months, I'm back to business with the V4, hope this time will be the good one...
The challenge was to put the bike back on wheels for Christmas :mrgreen:
so, I had to rebuild totally the fork:

I started to replace the inner and outer bush, one is Yamaha OEM, for the inner ones, it was less easy to find.
After few hours on the web, I found this reference:
Image

All I had to do was to "enlarge" the gap to allow the bush to be more flexible to enter in the fork.
To do that I used a small Dremel disk, and increase the gap to set the bush with exact diameter than the original (on left).
Without increasing the gap, the bush was large on the tube, and didn't enter the fork.
On the picture, the new one on the right like it was just after the dremel attack, then I tighten the gap to 2mm and put it on the tube.

New bush, on right the old were tired, seals and dust protect:
Image

Then I put everything together:
Image

Big moment, I put back the Wheel and the bike is back on ground, miracle :grin:
Image

And just for the pleasure, the new look with the brembo, I like it!
Image

Next step, the cranks are Under restoration, waiting them back and it will be time to rebuild the engine.
Best Regards :smt006
My bikes: Honda CB250K2 1970 / RD350Lc 57V 1985 / RD500Lc 47X 1987 / KTM 250 EXC 2005 /CB600N 2008

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Kalim
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Re: RD'll be back

#28 Post by Kalim » Tue Dec 23, 2014 5:14 pm

Salut Francis,

Nice job for the fork.
I like the Brembo style too !

David

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Speed Freak
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Re: RD'll be back

#29 Post by Speed Freak » Wed Dec 24, 2014 12:26 pm

Image

For this bolts i used a good tool and a (pneumatic) impact wrench.
Works better for rusty bolts than hand tools - the hexagon in the bolt is nearly undamaged.

For the future i want to buy an electric impact wrench from makita.
The neighbor of a friend has 2 of them and they have done a good job to remove rusty stud bolts from my RD350 cylinder block.
Combined with this one it should be easy to get them out:
Image
Stahlwille stud bolt remover... 140€... it`s christmas :smt003
My bikes:
RD500 YPVS 1GE
RD350 YPVS 31K 1985
Honda CBR 1000 RR SC57
Yamaha R1 RN04

rd84
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Re: RD'll be back

#30 Post by rd84 » Wed Dec 24, 2014 1:30 pm

Hi Francis,

Thanks for sharing your progress - its very valuable to people like me who are learning how to fix these bikes.

I found with the studs that if you put penetrating oil on them and leave to soak for a few days - then clean the oil off and heat the aluminium - but NOT the stud as far as possible - just use a blow torch with a small flame and play it on the aluminium - these studs often then come out with no damage to the stud - don't heat the stud too much though - as I found out it weakens the steel which then shears :shock: - I also found with that stud extractor type that you bought that they can slip and the teeth cut into the steel of the stud if you use a lot of force - however they are good - sometimes a tap with the mallet onto the extractor before trying to extract the stud seems to help - I suppose it must help break the corrosive bond between the metals ? - Anyway I have to say that I am sick of extracting studs this year ! :smile:

Good luck with your project and have a nice Xmas.

Cheers
Paul

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