SV650.org - SV650 & Gladius 650 Forum



SV Talk, Tuning & Tweaking Discussion and chat on all topics and technical stuff related to the SV650 and SV1000
Need Help: Try Searching before posting

Reply
 
Thread Tools
Old 28-11-10, 04:40 PM   #1
muzikill
Member
Mega Poster
 
muzikill's Avatar
 
Join Date: Jul 2005
Location: Dunfermline
Posts: 1,712
Default I'm a broken sv engine get me outta here!

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




... 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..


in particular these two first...


and this one as well....




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...

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 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.


as you can see a nice empty space!

All the engine bolts nuts etc. bagged and tagged


And heres the end result.....


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
__________________
Learn to maintain your bike, take it apart, rebuild the engine & more (using better bolts ), drop it & fix it again!
K3 Job c.v: Engine:remove/split/rebuild/refit. Replace:Gearbox,Fuel pump,Gaskets. Piston clean,rings. Overhaul:Throttle body,Injectors,Brakes,Forks. Remove/refit:Exhaust,Radiator,Oil cooler,Throttle,Air filter,Tank. Replace: Oil,Coolant,grease,brake hoses & bleed.
muzikill is offline   Reply With Quote
Old 28-11-10, 05:04 PM   #2
Drumming_Animal
Guest
 
Posts: n/a
Default Re: I'm a *ucked sv engine get me outta here!

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.
  Reply With Quote
Old 29-11-10, 07:13 AM   #3
zadar
Guest
 
Posts: n/a
Default Re: I'm a *ucked sv engine get me outta here!

Personally I take out all bolts except big one in middle.
  Reply With Quote
Old 29-11-10, 04:06 PM   #4
muzikill
Member
Mega Poster
 
muzikill's Avatar
 
Join Date: Jul 2005
Location: Dunfermline
Posts: 1,712
Default Re: I'm a *ucked sv engine get me outta here!

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!
__________________
Learn to maintain your bike, take it apart, rebuild the engine & more (using better bolts ), drop it & fix it again!
K3 Job c.v: Engine:remove/split/rebuild/refit. Replace:Gearbox,Fuel pump,Gaskets. Piston clean,rings. Overhaul:Throttle body,Injectors,Brakes,Forks. Remove/refit:Exhaust,Radiator,Oil cooler,Throttle,Air filter,Tank. Replace: Oil,Coolant,grease,brake hoses & bleed.
muzikill is offline   Reply With Quote
Old 22-01-11, 09:49 PM   #5
muzikill
Member
Mega Poster
 
muzikill's Avatar
 
Join Date: Jul 2005
Location: Dunfermline
Posts: 1,712
Default Re: I'm a broken sv engine get me outta here!

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.



And here is how it looks...



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



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



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
__________________
Learn to maintain your bike, take it apart, rebuild the engine & more (using better bolts ), drop it & fix it again!
K3 Job c.v: Engine:remove/split/rebuild/refit. Replace:Gearbox,Fuel pump,Gaskets. Piston clean,rings. Overhaul:Throttle body,Injectors,Brakes,Forks. Remove/refit:Exhaust,Radiator,Oil cooler,Throttle,Air filter,Tank. Replace: Oil,Coolant,grease,brake hoses & bleed.
muzikill is offline   Reply With Quote
Old 22-01-11, 10:43 PM   #6
zadar
Guest
 
Posts: n/a
Default Re: I'm a broken sv engine get me outta here!

27mm.
Make tool out of steel plates, just weld handle to plate.
  Reply With Quote
Old 23-01-11, 02:18 PM   #7
muzikill
Member
Mega Poster
 
muzikill's Avatar
 
Join Date: Jul 2005
Location: Dunfermline
Posts: 1,712
Default Re: I'm a broken sv engine get me outta here!

http://forum.svrider.com/showthread....+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
...
__________________
Learn to maintain your bike, take it apart, rebuild the engine & more (using better bolts ), drop it & fix it again!
K3 Job c.v: Engine:remove/split/rebuild/refit. Replace:Gearbox,Fuel pump,Gaskets. Piston clean,rings. Overhaul:Throttle body,Injectors,Brakes,Forks. Remove/refit:Exhaust,Radiator,Oil cooler,Throttle,Air filter,Tank. Replace: Oil,Coolant,grease,brake hoses & bleed.

Last edited by muzikill; 23-01-11 at 02:23 PM.
muzikill is offline   Reply With Quote
Old 18-11-11, 09:31 PM   #8
saintnick
Guest
 
Posts: n/a
Default Re: I'm a broken sv engine get me outta here!

So have a look at the pix of clutch basket here

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...
  Reply With Quote
Old 18-11-11, 10:44 PM   #9
DarrenSV650S
Member
Mega Poster
 
DarrenSV650S's Avatar
 
Join Date: Jul 2006
Location: Dundee
Posts: 4,414
Default Re: I'm a broken sv engine get me outta here!

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
DarrenSV650S is offline   Reply With Quote
Old 18-11-11, 10:49 PM   #10
suzukigt380paul
Guest
 
Posts: n/a
Default Re: I'm a broken sv engine get me outta here!

Quote:
Originally Posted by zadar View Post
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
  Reply With Quote
Reply


Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Broken Engine - Complete. K6 Noble Ox For Sale - SV's and SV related items 7 17-09-10 01:10 PM
Broken Engine Shanny SV Talk, Tuning & Tweaking 11 19-08-09 11:34 PM
Want broken pointy engine fastdruid Stuff Wanted 7 14-08-08 01:12 AM
I think i've broken my engine drag Bikes - Talk & Issues 24 12-08-08 10:45 AM
broken engine socommk23 For Sale - SV's and SV related items 3 11-11-06 03:13 PM


All times are GMT. The time now is 04:10 AM.


Powered by vBulletin® - Copyright ©2000 - 2025, Jelsoft Enterprises Ltd.