I'm a broken sv engine get me outta here!

[muzikill]

Ok, so here we are back again from the other threads i started on fixing a very unwell sv650s k3.
http://forums.sv650.org/showthread.php?t=156046
http://forums.sv650.org/showthread.php?t=156338


so, jack under the engine

http://farm5.static.flickr.com/4086/5214147611_bea2820f7e.jpg


... and worked my way through the official sv manual & the haynes taking out the bolts in the right order.. the bolts were easy enough.

it was the spacers that were the cause of much head scratching..
http://farm5.static.flickr.com/4128/5214741642_ceb0a4069c.jpg

in particular these two first...
http://farm6.static.flickr.com/5086/5214739862_39868a1409.jpg

and this one as well....
http://farm5.static.flickr.com/4110/5214739284_1c765cf9fd.jpg

http://farm6.static.flickr.com/5289/5214145763_52e28af563.jpg

I dont know if i was blind but as far as i could tell the manuals tell you how to remove the bolts and the spacer nuts but don't mention anwhere that you unscrew the hex headed spacers out of the frame and at the same time play a great game of balance the engine as it drops!

Going back a few steps...
http://farm5.static.flickr.com/4106/5214149473_e3811fdbf2.jpg
This one was of no particular fun as that is the last bolt you have to remove as it lets the engine pivot away when dropping it so the rear cylinder exhaust pipe doesnt drop on the swingarm and damage it.

The problem? - the special castle type socket i bought off ebay to take the locknut off isnt deep enough to reach it due to the bolt head :mad: the particular seller on ebay is the most popular one selling these....

So i ended up using a big flatheaded screwdriver and a hammer to loosen it off, luckily it worked!

Engine dropped pretty easily, took two of us to as the jack got in the way so we had to lift the engine up & kick the jack out of the way to ease it down.

http://farm6.static.flickr.com/5205/5214743694_873fe18278.jpg
as you can see a nice empty space!

All the engine bolts nuts etc. bagged and tagged
http://farm5.static.flickr.com/4133/5214253011_0b6013f8b5.jpg

And heres the end result.....
http://farm5.static.flickr.com/4130/5214742852_9bbaa36315.jpg

So, next up i think will be the chance to clean the parts of the bike that are hard to reach normally, especially around the swingarm.

It's game on as far as the winter project goes - now i can spend time stripping the engine to get at the gearbox and repair it :p

[Drumming_Animal]

Excellent, im looking at dropping the engine out of mine over winter and gettin roung everywhere and cleaning, and generally lubing stuff that needs lubing, check stuff that needs checking, tightening stuff that needs tightening, etc. More or less going through the Haynes manual and just giving the bike a damn good going over.

[zadar]

Personally I take out all bolts except big one in middle.

[muzikill]

I sh*t out of doing the middle bolt, i kinda thought it would be better keeping the middle bolt in but wasnt sure if it was that central with the weight of the engine plus doing what the manual said made sense at it allowed the engine to lean forward, if i had crushed the rear pipe on the swing arm im sure the bank balance would hate it!

[muzikill]

http://forums.sv650.org/showthread.php?t=161655

So, after do a cleanup as above i was ready to remove the clutch cover - wasnt too bad. it took a bit of 'gentle persuasion' to get the thing off! (it was getting stuck on the dowels and the gasket was holding it on more than i expected.

http://farm6.static.flickr.com/5286/5379018946_ba693923ce.jpg

And here is how it looks...

http://farm6.static.flickr.com/5003/5379019462_63e505e94e.jpg

Noting what sequence the washers go on on this...

http://farm6.static.flickr.com/5047/5378420485_2959ffcf7e.jpg

Clutch out, looked fine, no broken plates - i will check the measurements for tolerances...

http://farm6.static.flickr.com/5244/5379020290_0b601ed24a.jpg

Ok, so this is where i got to today (i know im taking my time!)
I also loosened the bolts on the starter motor and the cam covers ready for the next stage.

Does anyone know what size for a socket the clutch nut is? - i looked in the haynes & official manuals but no sizes are in it (a rough measurement says around 26mm. And what methods you have used to hold the clutch cage to allow you to loosen the nut? - i'm scared of damaging it.

Plus any advice on the way to clean the residue gasket off the clutch cover carefully?

Thanks in advance :D

[zadar]

27mm.
Make tool out of steel plates, just weld handle to plate.

[muzikill]

http://forum.svrider.com/showthread.php?t=49890&highlight=factory+pro+shift+kit

Found a thread that shows an easy tool to make! - now i have to find the bolt sizes - i dont want to use clutch bolts (as they dont look very strong)

Edit: 6mm 25-30mm in length
...

[saintnick]

So have a look at the pix of clutch basket here (http://forums.sv650.org/showthread.php?t=171948&page=2)

How does yours compare? I know its pointy and mine isn't but I've just discovered that even with a relatively small amount of wear it can cause dragging... if new plates are going in it may be worth be giving the basket a make over...

[DarrenSV650S]

I was about to say SNAP! we are doing the same thing just now, but just noticed this thread is from last year. It took you a year to clean up the engine? lol ;)

[suzukigt380paul]

27mm.
Make tool out of steel plates, just weld handle to plate.

no tool needed just undo it with a impact 18volt or air,about 5 seconds with one of these and its off,same with the front sprocket

[muzikill]

Should i have updated this?..... I used the homemade tool to remove it but ended up buying the proper clutch holding tool when refitting it..... The bikes been back on the road for 6 months :)