My engine R&R progress

[kinger]

nos-pro - LOL

Highmiler, thanks for the suggestion, if I'm in there I'm too anal not to put the $36 in parts to have it good again, I will remember that though if I get in a pinch when the snow is flying!!

srxpert - I love working on stuff, someday I want to go to a technical school just to have the knowledge to do my own projects. Till then engineering pays better or I would have skipped the 5 years of school for that LOL

 

[kinger]

Engine out!

Finally got her out today. The lift was cake, I was expecting 200 lbs and it was more like 120-140 I would guess. If a guy could get the right angle on it you could probably lift yourself.

The engine is dropped off at the yamaha dealer today for a full waterpump tear down and replacement and hopefully find the leaking crack on the block they can TIG weld it and I'm good to go. Dont mind all the wiring it looks worse then it is with the nitrous harness and LED harness.

Next up I'm swapping my front suspension, rear suspension, track, replacing all jackshaft and drive shaft bearings. Polishing the tunnel and fixing some small plastic windshield bits. The clutches are being sent to ulmer racing for inspection as I am not comfortable with servicing clutches. The top of one sheave looks warped! I'll keep updating as I go through I will need some help on the jackshaft stuff. Thanks!

 

[Custom Sled Shop]

sled

Fun EH?? good job! its more fun puting it back in!

are you going to powder the bulk head? Nows the time! your half way there,

Goood luck on the motor,

 

[kinger]

Yeah I am wondering if I should just go full monty, I know a local powdercoater. I want to do sometihng with the steering gate as that is more visible, black or polished, chrome, etc. Not sure yet, ideas welcome!

 

[FAMILYMAN]

Those rivets are a pain in the ....Come pick up my chassis if you want to powder coat it. Then drop your engine into mine. Its just sitting in the shed. I have been trying to give it away for awhile now.

O ya, I put the engine back in by myself. It was a good workout, dont recommend you do it tho.

Got the clutch puller back, thanks for returning it so quickly!

Could have just left the clutch on, but cheap insurance taking it off. Hate to see it come back broke from the dealer.

 

[kinger]

I couldn't remove the engine with out the clutch because the bolt was pushed in from teh clutch side to the mag side so it would only slide out and hit the clutch...

I will place the bolt in the proper direction the next time

 

[kinger]

Start of apex front suspension

Starting the apex GT front suspension swap, then on to the chain case/bearings, etc and extro drivers and track swap, then ready for the engine to go back in. I'll install with edge skid unless my ZX2 shows up which would be mint!

Clutches needed major repair and ulmer is hooking me up, thanks spec

Also Damn you custom sled shop, you talked me into it and I dropped off some goodies for powder coating!!

 

[kinger]

Got the apex front end all buttoned up, with as much grease as I could shove in the all the A arms and metal bushings, all new bushings. There is NO slop in the front end now. I was surprised because the apex hardware actually needed new bushings and I can't believe there is more then 500 miles on them. All good now!

I degreased the entire chassis and boy was she dirty, eveything looks new again! I also installed my new skid plate nutserts so that will bolt right up when its all done.

I flushed the coolant system, I had a hodge podge of crap in there and deposits everywhere so I flushed the system clean and LOTS of crap came out and now she spotless. I flushed the engine as well.

Engine is done, $136 in parts and NO tig welding, the initial assessment was wrong that it cracked a mounting stud, the housing cracked but that is a replaceable part. So the waterpump is new, everything, every seal, etc. I hope that little temp seal seals up quickly on start up and this never leaks again! Makes me happy that I don't have a 'disfigured' block or anything. Everything is factory yamaha except the ARP studs and she was such a good runner I expect a lot of miles out of this baby.

I also added my simmons skis and they look tight with the black/silver combo. I love the simmons mounts over the C&A I had before this, everything bolts up nice and tight.

I'll get some more progress pictures up. I'll need some help on assembly I hope I can count on TY!!

 

[kinger]

Here are some pictures, also if the clutch sheaves look new its because they are! Both sheaves on the primary were cracked and ready to blow. good thing I didn't let them go with the first shot of nitrous!

Clutching is Polaris 10-62 weights ground down to fit, a O-S-O primary spring and a Polaris Blue Secondary spring. Sort of unorthodox, but that is how it came from CB performance and I aint messin' with it.

the front end looks so much better in person, yes its pigeon toe'd right now there is no steering hooked up

I hope somebody cares that I keep posting LOL I feel like I'm talking to myself LOL...still good therepy I guess... :exc:

 

[Turtle]

Lookin good so far! Don't worry - your not talkin to yourself ... only crazy people do that!

 

[Srxspec]

That primary looks familiar! LOL!

 

[kinger]

LOL thanks guys.

Thanks SRXSPEC for the clutch rebuild, they looked great. BTW did you ever figure out the helix angle?

 

[maim]

lookin good!

 

[kinger]

Made some real good progress so far, the Apex front is done, the steering gate is back from the powder coaters and installed, engine is secured, steering system is installed and tight, just need to align it. Gas tank is also in.

Tommorrow I'm going to get the bars back on, the coolant system, and the fuel system, then figure out some the wire routing and work on the nitrous. Going to get some wire loom and make all the harnesses look better.

Things go back together much faster then coming out, course maybe I'm excited and working at 110% productivity I should have most the plastic on and have it look like a sled again after tommrrow, I'll get some pictures!

 

[rxrider]

Looking good, please post more pics of your install. You're not alone - looking at you working on your sled makes me wanna go to my garage to take care of my baby

I have to change out all bushings in the front end and install Fox Floats. A new smaller lightweight battery is going into the bulkhead, I'm removing the steel battery bracket. Also have the ZX-2 on order to install when it arrives.

Jan
rxrider