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1:11 YZ250F 2019-2023 Full Motor Rebuild (Part 3) Crankshaft installed engine installed in the bike. — Transcript

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0:01welcome back to the shop this is part
0:03three of the 2022 YZ 250f full motor
0:08rebuild in this video I'm going to be
0:10pulling the bottom end out of the bike
0:12putting it on the bench taking it apart
0:14putting a new crankshaft in and all that
0:16putting it back in the bike and then see
0:19how far we get probably get the cylinder
0:21head on and stuff like that maybe get it
0:23started up today maybe on tomorrow's
0:26video we'll see how far we get
0:28today some of the things I did this
0:30morning before I started filming just to
0:32kind of save time was I moved all the
0:35studs like I mentioned the last video
0:37over to from the old cylinder to the new
0:39cylinder and I also moved the intake
0:42manifold here I did a little blue
0:44printing with that what I mean by that
0:46if you put the bolts in but you keep
0:48them loose you can wiggle this around
0:50there's a little bit of play there what
0:52you want to do is you want to move it
0:53around until you get until you find that
0:57it matches the opening of the intake on
1:00the head this manifold matches it
1:02perfectly the best you can and then you
1:05snug them down of course I use lock
1:07locktite on these you don't I'm sorry
1:09thread Locker on these you don't want to
1:11use uh locktite because they're known to
1:13shut down riding area so we use thread
1:15Locker instead
1:17H I also put the valve shims on each
1:21valve uh we're not sure if they're the
1:23correct ones yet they're just ones that
1:25were originally in that head we'll be
1:27shimming the valves in a little bit with
1:29the uh cam the new cam shafts in but I
1:32put them in place with the buckets and I
1:34just set this on here the cam caps for
1:36the time being I'm going to set the head
1:38aside for the time being and uh we're
1:40going to worry about adjusting the
1:42valves a little later cuz this point I'm
1:43going to treat it like if the crank went
1:45out so I'm going to focus on getting a
1:47new crank new bottle in together and
1:48right before I put the head on then I
1:50will check and adjust the valves so uh
1:54yeah let's dig
1:55in in the last video when I was going
1:57through the parts I think I forgot to
2:00mention that we also got a new cylinder
2:03for it now um this is another reason why
2:06I speculate this top end came from a
2:09different bike and it was just may maybe
2:12don't know maybe not accusing anyone of
2:15anything but I'm just going by what
2:18evidence I have here and we you know
2:20again my goal is just to make sure this
2:22bike is safe for the rider the best that
2:24we can but part of the reason I believe
2:26it because if you look this is a brand
2:28new cylinder has really good C cross
2:30hatching and that cross-hatching kind of
2:32hangs in there for quite a while which
2:33is good I have a video on cylinders
2:36specifically if you check down in the
2:38description there'll be a link to that
2:41um but if you look at this cylinder it
2:43most the cross-hatching is kind of worn
2:45away where where the uh where the Piston
2:47rides on it at and I typically don't see
2:51this level of cross-hatching worn away
2:54until above like 100 hours on a 250f
3:00so that's what kind of leads me to
3:03believe that maybe there was a modified
3:05cylinder head and everything on this
3:07bike and then to sell it they might have
3:08swapped it out and just grabbed whatever
3:10parts from whatever 250 F they had on
3:13the shelf and kind of just tossed it on
3:15sent it out the door I don't know I'm
3:17not accusing anyone anything like I said
3:18I'm just working with what I have here
3:20and trying my best to put this thing
3:22together as good as well as I can to
3:24make it good and safe and reliable for
3:26Joey all
3:28right and because if that was the case
3:31that the cylinder head and the cylinder
3:33from another bike that information would
3:34have been good for us to
3:36know because as a race bike you have to
3:39replace valves every 200 hours or you
3:41should for safety reasons and valve
3:43springs cam shaft no matter how well
3:45they test out when it's a race bike
3:47being used on the track with
3:49jumps so you know we don't know how many
3:52hours W this head or whatever we don't
3:54know if it came if it's original from
3:56this bike or not but based on what I'm
3:58seeing on the cylinder I'm questioning
4:01if it was original or not we don't know
4:04okay the brand new cam shafts here I'm
4:05going to do my best to scribe a line
4:08between the cam shaft right here and the
4:11gear so if it ever if a valve does ever
4:14hit the Piston again we'll know if this
4:17gear shifted on the cam shaft that'll
4:19let us know if the cam shaft needs to be
4:21replaced or is it reusable again now I'm
4:23not an artist so it's going to be tough
4:24for me to get a nice good straight line
4:26here but I'll do the best I
4:28can
4:30oh let me get some better
4:33glasses all
4:37[Music]
4:43right okay again I'm not an
4:46artist so I scribed the line right there
4:49with that little grinder but that you
4:51know that thing kind of sucks so I also
4:54put two uh with the Sharpie now
4:56typically the Sharpie lines will stick
4:58around
5:00I I know because when I Mark cylinder
5:02head bolts inside the motor I see the
5:05Sharpie line years later still there so
5:08typically it it sticks around but for
5:10whatever reason it doesn't we also have
5:13that to go by the scri mark and then
5:16same thing here on this one the intake I
5:18put two Sharpie lines one right there
5:20one right there and two scribe marks one
5:23right there again the Scribe marks
5:25aren't that
5:26perfect better than nothing so I'm going
5:28to be relying more on the Sharpie but if
5:31for some reason it disappeared we at
5:32least have that and that's going to let
5:34us know if these cams ever shipped if
5:36for some reason the valves ever hit the
5:38Piston we don't want that now here's the
5:40old cam shafts and uh what I'm going to
5:42do now is see if these are junk or not
5:46are they good or are they trash CU these
5:49could be good backup cams if we ever
5:51need them and since I have some brand
5:53new ones here I'm just going to eyeball
5:55them honestly I'm not going to break out
5:56a degree wheel and all that cuz when
5:58they shift they don't just shift a
6:00little bit when they finally get enough
6:02Force to shift that gear it's not a
6:05little crack it's uses a it's uses a
6:07good little amount it takes so much
6:09force to get it to Shi that when it
6:10finally gets there it budges pretty good
6:13so um let me see
6:16here the beauty of marking them first
6:18too is I won't get these CS mixed up
6:20between the old one and the new ones all
6:24right uh let's see you got to kind of
6:27get a little bit creative when you do
6:29this
6:31what I'm going to do is look down these
6:33two teeth right here I'm going to set my
6:35eye at a straight angle where I'm
6:36looking down through here and I'm going
6:38to see what matches up to these with
6:40that there just see if it get shifted a
6:42little
6:49bit okay let me compare it to this
6:58one
7:03H let me take a better look okay I'm
7:06going to say the intake cam was good so
7:09that's good I'll put the
7:12uh I'll put the cam shaft in the Box
7:15here with this
7:19bag and we'll save that as a
7:22backup it's looking
7:25good okay now let me compare the exhaust
7:28cam same thing I'll the loes here kind
7:30of line my eye up to it and look down to
7:33see where matches these
7:36teeth compare it to this
7:43one sauce cam shafts look good too so
7:46this again will be a good backup cam
7:48shaft if anything ever goes wrong with
7:51the cam the new ones we're putting in we
7:53always have these old ones to fall back
7:58on so there we
8:01go and while I got cylinders here might
8:03as well move
8:04this uh plug right here from the old
8:07cylinder to the new
8:10one okay new crank and new crank
8:13bearings I'm going to go ahead and go
8:15put these in the freezer now let them
8:17get nice and Frozen because when metals
8:19get cold they become smaller they
8:21contract that's going to help ease our
8:23job when it's time to put these in the
8:25case and the crank will be cold so it'll
8:27help ease our job when it's time to put
8:29the cases together it'll slide right in
8:31these crank bearings much easier so let
8:33me go ahead and put these in the
8:36freezer all right time to start working
8:38on getting the bottom end Out start by
8:40getting the shifter off of
8:42here that way I can remove the Stater
8:45cover cuz I'm not going to follow them
8:46wires up and disconnect the stator so I
8:49can remove the whole motor with the
8:52Stater cover on there I'm just going to
8:54unbolt the Stater cover that has the
8:56Stater electrical wires connected to it
9:00and just hang it off to the
9:05side there we
9:09go
9:11okay pop the Stater cover
9:17off Stater cover has these but there's
9:20little Nubs where they go I'll show you
9:21better when it's time to put it back
9:24together to kind of let you know where
9:26they kind of remind you where they're
9:28supposed to go
9:29it's trying to put it
9:33together and then also it has these
9:36copper washers on some of the bolts they
9:39typically will put an arrow pointing
9:41where the copper washer is supposed to
9:43go so that
9:45will indicate to us when it's time to
9:48put back together where they
9:54belong
9:58okay
10:05it's kind of magnetic when you pull it
10:07off it's trying to stick to the flywheel
10:10so you'll feel that I'm just going to
10:12let it dangle right here nice and
10:17gently PA needle nose and pull them
10:23out there we go there should be one over
10:26here on this one
10:28yep
10:33all right pull the gasket
10:39off pull this cover
10:48off okay let me go get the front
10:50sprocket off of there I'm going to try
10:52to keep the chain on the bike if I
10:57can just pop that that up using old worn
11:02out Flathead get
11:04started then I'll break out the
11:11punch all
11:14right this should be a 24
11:21mm and this is where impacts really come
11:24in handy if you don't have one I highly
11:26suggest getting one for a job like this
11:28you don't need a air impact you can use
11:31one of these uh battery ones that I have
11:34here I picked that up at Harbor
11:36Freight for like 59 bucks I saved that
11:39one for when I'm at the track and have
11:41to do stuff there but I use air at home
11:44but yeah you can pick one of them up for
11:4559 bucks if you don't have a compressor
11:47and all the Airlines and everything for
11:49air impact but it definitely makes
11:51things like this quicker and
11:54easier okay you so I was able to take
11:56the front sprocket off and just set the
11:57chain there that's just going to to make
11:59it where we don't have to remove the
12:00[Music]
12:02chain all right let me get this sensor
12:05off
12:09here just like I said it's for me it's
12:12just easier to pull the sensors off the
12:14motor instead of following them all the
12:15way up to where they connect up behind
12:18the radiators cuz then you got to pull
12:19the radiator off and all that it's just
12:22easier this
12:24way now when you pull this up and off
12:28there's some parts in there that we need
12:29to collect real quick so they don't fall
12:31out while
12:33we're I'll show
12:40you you want to collect this the little
12:44pen there with the spring sometimes the
12:46spring oh the spring stuck in there
12:47pretty good sometimes the spring will
12:49stick in there and you'll have to fish
12:50it out but you want to collect that so
12:53it doesn't fall while you're pulling the
12:54motor
12:56out okay uh yeah let me get this off
12:58there
13:09chickens are going crazy out
13:18there there we
13:23go I'll go ahead and pop the starter off
13:26too cuz it's really close to the spring
13:30and when it's time to pull this motor
13:32out um it'll give me a little more
13:37room go to the other side get the
13:39starter some love
13:57caps
13:59all
14:02right there we go they have these little
14:05pins right here roll
14:07pins and on to the other side of the
14:09motor let me go and pull this
14:12off oh I forgot to mention I did drain
14:15the motor oil that's why you're not
14:16seeing oil come out when I took off the
14:19stator went ahead and got that out of
14:21the way this morning off
14:27camera
14:29okay let me get these hoses
14:32off okay now I need to remove these
14:34motor mounts right here the one down on
14:37the bottom and remove the swing arm
14:39pivot bolt that goes right to the motor
14:41right here which means I have to remove
14:42these covers so let's go ahead and do
14:57that
15:27what
15:40okay it's time to knock the swing on
15:42pivot bolt
15:43through for it to come out this side we
15:46either have to remove the brake lever
15:48here or get it down low enough the
15:50easiest way to do that so we don't have
15:52to remove the brake lever is just to
15:54separate the pads a little bit
15:57here
15:59cuz when you separate the pads
16:01watch then you can lower it real low you
16:04only get a couple
16:05times but yeah let's do that let's do it
16:08that
16:09way and of course if you do it this way
16:12when you're done and you put the bike
16:13back together make sure you pump that
16:15brake back up and I'll remind you at the
16:16end that way in your first ride you
16:18don't go for the back brake and you
16:19don't have one until you pump it a few
16:21times okay time to knock The Swinging
16:23arm pivot bolt through I'm just going to
16:25use this long bolt that it will kind of
16:27sit right in the middle here and it
16:30won't damage the threads because they
16:31actually purposely give it a pointy end
16:34cuz
16:36they I'm going to watch it on the other
16:38side when it gets close to the brake
16:40lever I'll just press the brake lever
16:47down collect that washer right
16:55here okay it's starting to get to the
16:58brake left so let me go to the other
16:59side and press it down with my
17:16foot there you go I got the head past
17:19the brake lever so we're good
17:27now
17:30now I don't want to knock that swing arm
17:32pivot bolt all the way out cu I want it
17:35to
17:36be let me show you I need to go about
17:39that far because I want it I want it to
17:41hold the swing arm still on the bike so
17:43all I have to do is knock it far enough
17:45out where it releases the rear of the
17:47motor here but I want the right side
17:49over there to hold the swing arm still
17:51on the
17:57bike
18:02that'll that'll save us work at the end
18:04so we don't have to line the swing arm
18:06up back up all we have to do is just
18:09knock the swing swing arm pivot Bol back
18:11Bol bolt back in you can see I just left
18:14it there it's underneath the brake lever
18:17here and uh yeah I think we could just
18:21pull the motor out now let's
18:24see here we
18:27go
18:35I have this hose here here we
18:45go all
18:50right it is on the healing bench I have
18:54that turkey tray underneath it you know
18:55there's always a little bit of motor oil
18:57leftover so when we open it up just want
18:59to catch that instead of dirting all my
19:02Rags okay let me start by getting the uh
19:04flywheel off here now in my previous
19:07videos I always mentioned you need an
19:08impact to get this off and one of my
19:10subscribers actually made me aware that
19:14there's actually spot that you can get a
19:16wrench right here and hold this flywheel
19:18from spinning if you're just doing it by
19:19hand or when it's time to torque it down
19:21a torque wrench never even notice that
19:23and it shows it in the manual I just
19:24glossed over it so quick but all right
19:27let's but I'm going to use it impact cuz
19:28I have one and that's how it
19:30goes quicker
19:33easier of course as I say in all my
19:35videos I'm real cautious where I use an
19:36impact during reassembly because it is
19:38really easy to strip stuff out with the
19:41impact all right fly wheel puller what
19:44size is this one let's see if we can
19:47figure it
19:48out I got several pullers here I just
19:51have to figure out which size it
19:54is appears it's this size right here let
19:56me show you guys for video sake uh holy
20:00cow it doesn't have it written on it
20:01well down in the description check in
20:03there I will include the size puller
20:05this bike takes if you're uh doing this
20:07job and you need you need that
20:09information usually they have it written
20:11on them but guess not on this
20:24one and there we
20:27go get that sucker right up off
20:30there and this flywheel puller got stuck
20:33on there let
20:35me that's how you do
20:37that okay I want to collect this keyway
20:40right here don't want to lose that we're
20:42going to need that for the crankshaft
20:43the new crank shaft
20:45obviously go get the timing chain on out
20:48of
20:52there there we
20:57go
21:06actually let me twist this one out by
21:08hand I I've had these strip out on me
21:11before using an impact and I don't want
21:14to risk that
21:21today God dang they
21:27tough
21:29there we
21:30go holy cow that thing was in there good
21:33they locked tight them in real well and
21:34we will be doing that too when it's time
21:36to put it back
21:41together all
21:43right slide this on
21:46out and
21:52down get timing chain tension on out of
21:55there I'll set that over there
22:01the old timing
22:03chain this timing chain is in great
22:06shape by the way but we still have a new
22:10one all right go ahead and remove this
22:13counter
22:14balancer looks like that's a 19
22:20mm I'm going to hold the crank while I
22:23do that so it doesn't go spinning around
22:24and damage the uh the cases
22:29all I do is just hold the rod
22:38there there we
22:45go move that 10
22:47mm this is just a a screen a filter
22:52catches everything before it gets into
22:54the oil pump you really shouldn't find
22:56anything in here um um that's just dirt
22:59okay if you do find anything it might be
23:01some Yama bond from
23:03assembly when they put the motor
23:05together sometimes I do find a little
23:07bit of that in
23:09there or if you're taking your motor
23:11apart because your crank I mean your
23:13transmission took a crap on you and you
23:15can find it in
23:16there find all kinds of metal
23:20stuff okay I'm taking this side of the
23:22case bolt bolts out now and we still
23:25have to go to the other side
23:29strip all that off over there but I
23:31might while I got this side in my face I
23:34might as well take these
23:39out let me get them all I'll be right
23:42back all righty now when you remove
23:45these there are two that are easy to
23:46miss and I actually just missed one and
23:49I'll show you which one that
23:53is this one's easy to miss right here in
23:57the middle cuz we always think they're
23:58always going to be on the Outer Edge
24:00right so it's easy to miss that one in
24:01the middle but there's also another one
24:03up in here that I actually did Miss
24:06there we
24:09go all
24:11right okay time to remove the clutch
24:26cover
24:36go get the oil filter out out of there
24:40now that's going in the trash we got a
24:44new filter to put
24:47in
24:52okay you'll know if you have all the
24:54bolts out for this clutch cover if you
24:56missed one cuz you'll see that I left
24:57like these in and stuff and the water
25:00pump ones
25:01in but you'll know if you're missing one
25:03cuz they won't come off very easily it
25:06should just come right
25:08off this is not a Honda where they use
25:11them gaskets that are literally like
25:14[Music]
25:20glue okay let me pull these
25:23out going to lose
25:26them
25:32technically these gaskets are often
25:34times reusable they're actually designed
25:35to be reusable if you had to um they're
25:38just a steel shim gasket with a rubber
25:41coating on both sides but we'll be
25:43replacing them however if yours are are
25:45newer and fresher let's say you just
25:47have to take your clutch cover off on a
25:49low hour bike for for whatever reason
25:52you'll be fine you're using it I can
25:54pretty much assure you that it'll be
25:56okay
26:01let's get the clutch
26:15[Applause]
26:25off all right so somebody has been this
26:27clutch
26:30before because to my
26:33knowledge Yamaha does not take the
26:37time to line up all of them on the the
26:41little Groove in the clutch plate
26:42typically Yamaha doesn't take the time
26:44to line all them up I do it's OCD
26:49thing could be wrong though maybe in
26:52this year they started doing that but I
26:54don't remember ever seeing them lined
26:56up
27:01hope you're watching what I'm doing here
27:02there's a little ball bearing in there
27:03you don't want to lose that
27:08thing see
27:17there all right let's remove that oh
27:21commercial break busted someone's been
27:23in here before you know how I can tell
27:25that one thing I do know Yamaha does
27:31is when installing the clutch plates the
27:33steel plates they're
27:35stamped to cut them out right and the
27:37sharp end right here you see how how
27:40it's sharper on this side on this side
27:42these are rounded off on these sides are
27:44sharp you're supposed to put the rounded
27:46end towards the motor like that not like
27:49this and I'm finding these like this
27:50which means someone's been in here and
27:53even though they took the time to get
27:55them line them lined up which make no no
27:57difference at all if you line them up
27:59it's the OCD thing but they didn't get
28:01the steel plates in right they had
28:03actually had them backwards now really
28:05all that affects if you put them in
28:06backwards is you'll have a little more
28:09clutch drag I guess you can say when
28:10you're letting the clutch out and the
28:11bike starting to grab if they're if
28:14they're angled this way it smoothens the
28:15engagement when you're letting the
28:17clutch out it allows the while the
28:18clutches are starting to transfer power
28:21it allows them to keep censing down all
28:23the clutch plates without these things
28:25snagging onto the the grooves in here
28:27just makes it a smoother clutch
28:29engagement that's
28:31all but that's how they come brand new
28:33every bike I read in a manual Yamaha
28:36manual I forgot which bike it was but
28:38they actually mentioned to put them in
28:39that
28:42way that's how you're supposed to do it
28:45and every Virgin bike Yamaha I've ever
28:48pulled apart that's how they are but
28:50this one is not which means someone
28:51truly has been in
28:54here okay I don't know if you know I'm
28:56there's a walk I'm sitting here talking
28:59and uh not explaining what I'm
29:10doing okay let's just grab this whole
29:15thing when you pull it up there will be
29:17a a a sleeve in
29:23here and this thing right
29:26here
29:28there we go collect
29:37that we'll worry about getting them
29:39clutch plates right when it's time to
29:40put together I'm going to pull out the
29:41shift shaft now when you pull this out
29:44you want to check for a washer down here
29:46appears they don't have one on this
29:49bike okay so we don't have one in this
29:52bike but they do have this spacer right
29:55here and you don't want to lose that
30:07okay what is
30:10next we didn't have a bottom-end
30:13failure and uh so there's like no motor
30:16I mean there's no metal chunks or
30:18anything in the motor oil so I'm not
30:19going to be worrying about this oil pump
30:20but because I know I will be cleaning
30:23this motor there's a little
30:25rubber thing right here let me see if I
30:27can get it out sometimes these like to
30:28jump out while you're trying to clean
30:30the bike or the motor so let me
30:36uh and it just fell on the floor there
30:38it
30:40is I want to grab that now so I don't
30:42lose
30:44it put that over
30:48here go slide this one out of here this
30:51torque limiting doohickey
30:56deal
30:58okay 22 mm I'm going to grab the rod up
31:02here up top so the crank doesn't go
31:10spinning there we
31:12go knock this one off over here
31:17too there we
31:23go start by pulling this off by the way
31:26let me verif
31:27that they were lined up properly cuz
31:29we're going to have to time in this
31:30counter balancer when it's time to put
31:32it back together okay yeah it's timed in
31:35proper there's a DOT there and a DOT
31:36there when them teeth line up so okay
31:38I'm just double checking everything now
31:41a bike that at least I was under the
31:43impression it was a virgin um we're
31:46starting to find out that it really
31:47wasn't a
31:49virgin this one's been dug into
31:52before anytime they have stuff stacked
31:55up like that a certain way I do like to
31:57take a zip tie put it through
32:00it that way when it's time to put it
32:02back
32:06together
32:08okay I'll do the same thing for this
32:10stuff right here
32:14too oh man we do have to take the oil
32:17pump off it looks
32:20like or do
32:22we oh yeah it looks like we will have to
32:24pull the oil pump out to get that out I
32:26mean technically I can split the cases
32:28when I remove the crank pull that out
32:30and then um when I'm putting it back
32:32together but you know I'm just going to
32:34pull it
32:37[Music]
32:43out another reason I'm going to pull it
32:45out is because again now that I'm
32:47finding out the motor is not a virgin
32:49someone's even been in the clutch
32:54area my biggest concern actually she's
32:56not the oil pump I know the oil pump's
32:58good it didn't have oil pump failure but
33:00if they had lock heght on the threads
33:01and it looks it appears they did that
33:04actually my biggest concern if I'm going
33:05to pull these
33:09out might as well pull the oil pump off
33:17too oh oh whoa don't go anywhere okay
33:21that's as far as I'm going to go with it
33:22I'm just going to peek up in here and
33:24see how everything looks let me get it
33:26cleaned up real quick
33:28all right everything's looking
33:29good she spends nice and freely I don't
33:32see any gouges or scratches up in here
33:35so it has that one bolt right there and
33:38I can actually see that's got locked
33:39heght on it right there so I'm not going
33:40to take this apart plus it looks like
33:42there's Factory lock tight on it right
33:44here so I don't think anyone's ever had
33:46the oil pump out before and that's good
33:49just wanted to make sure but now we can
33:50get this little turd
33:55off set set that right here with these
34:01parts okay I think it's time to split
34:03the motor
34:06now all right just going to look over my
34:09work real quick by the way I think I
34:11have a magnetic oil drain plug through
34:14this which I'll be putting in if I do I
34:16believe I
34:19do double check over here one more time
34:22that I have all the hardware
34:24out it's looking good sever ways to
34:27split this motor you can break out of
34:29Set It uh engine case
34:32Splitters or you can just do what I'm
34:34doing right here I take some long
34:36hardware and I screw them into the holes
34:39here and I bottom them out grab another
34:42one one one up in the front corner right
34:44there and one in the back corner
34:48somewhere and that's just going to allow
34:50me to tap tap the cases apart with a
34:53hammer and don't worry you can't hit it
34:55too hard cuz these will Bend if you hit
34:57them too hard you're not going to damage
35:01anything and the beauty of this is if
35:04you did forget a bolt somewhere you're
35:06going to find out because instead of the
35:07cases splitting you're just going to hit
35:09hit hit and nothing's going to happen or
35:10you'll start bending one of these but if
35:12you have it right let's
35:14see see already started splitting if
35:17everything's good it'll just split up
35:19for
35:25you
35:34give a little counter shaft right there
35:36just some love
35:38Taps kick that over a little bit I think
35:41that's it we can remove
35:44these so yeah you don't have to have
35:46case splitters for this motor for many
35:48of your two your uh Motocross Motors I
35:52have Cas Splitters here they're just
35:53they take so long to hook up they're
35:55cumbersome and it's it's really
35:57unnecessary when I can just slide two
35:58bolts in here and not plus I I honestly
36:01believe this is safer problem with case
36:03Splitters you start torquing on it and
36:06if you forgot a bolt you don't really
36:07feel it right away and you're just
36:09yanking on it you
36:12know looks like the crank's sitting on
36:14the right side here so I'm going to set
36:16the motor up like this a little
36:20bit oh you know what I forgot inside the
36:23shaft here for the clutch this piece
36:25right here just slipped out
36:28all right back at
36:30it I might have to give the counter
36:32shaft some love Taps
36:44again well that counter shaft's really
36:47hanging in there let me let me get a
36:49punch and keep punching it
36:55through
36:58there we
37:07go okay let move the camera back a
37:10little bit more so you can see
37:11everything that's going on
37:13here what I'm checking for real quick is
37:16washers did a washer stick here or here
37:18did they put washers in this motor the
37:21washer sit here or here no uh make sure
37:23both the Springs are here yes they are
37:27sure I'm the seat slide that transission
37:30back in its
37:32place I'm just making sure that we're
37:34not going to miss anything when we pick
37:35it up off this tray nothing's going to
37:38fall out it's real important to do that
37:40oh might as well get this out of here
37:42can you see that on camera yeah there we
37:44go that's the counter balancer now you
37:47got to remember which direction this
37:48goes in when it's time to put it back
37:49together right so we're going to
37:52remember that the blind end goes on the
37:58um the right side of the
38:06motor I'm going to take a sharpie and
38:08just put a r
38:11there this will just help me when it's
38:13time to put it
38:15together there we
38:18go now I know it looks like a mess and
38:21stuff but stuff like this is real easy
38:23to forget when it's time to put the
38:24cases back together and you have the y
38:26Bond on you stick them back together and
38:28you're like oh my God I forgot this and
38:30you got to take it apart and clean off
38:31gooey Yamaha bond that hasn't even dried
38:33up yet it just you're going to lose an
38:35hour and a half doing that so what I
38:37like to do is make a pile a dedicated
38:39pile like you see these little roll pins
38:41right here and I make a dedicated pile
38:44to the stuff that I have to make sure is
38:45in the motor before I put it together
38:48obviously you're not going to forget a
38:49big crankshaft it's just a little stuff
38:51and for this motor so far that's all I
38:53see as necessary stuff that needs to be
38:55in here
38:57and besides transmission obviously
38:59before we put it back together all right
39:01let me clean up my mess here
39:04along okay and I'm
39:07back I'm going to take a minute I'm
39:10going to expect the transmission now I'm
39:11not going to pull this transmission out
39:13there's no reason to As Long As
39:14everything's looking
39:16good and I can see everything in there
39:18so all I'm doing is I'm looking for any
39:21where that's not acceptable any anywhere
39:24I can see a problem area I'll give you a
39:27better uh idea what I'm doing in a
39:29second here because I if I see any gears
39:32worn oh we're going to replace
39:39them this one's not neutral is it no
39:41it's not let me put it neutral real
39:46quick let's
39:50see me slide all this back
39:55together
39:59it was probably neutral when I pulled it
40:00off the bike but that's how that goes
40:02sometimes let me get the gear
40:06shifter I think when I was taking the
40:07gear shifter off I might have bumped it
40:09into
40:17gear all right let's see what gear
40:23in anytime you shi them like that on the
40:26Ben you got to keep pressing pressing
40:28the shift Forks back in place I mean the
40:30shift pins back in place to hold the
40:34okay that was in that's the first gear
40:36now go halfway up the shift pin's back
40:39in place they like to pop out okay now
40:42we're in neutral because I can spin this
40:43shaft right here the main shaft and hold
40:46the counter shaft and doesn't spin so
40:48we're good there that's going to give me
40:49a better view of all the
40:51gears mainly the teeth on the gears I'm
40:53looking at
40:55everything
40:57that's looking
41:00good one back there is looking
41:05good that one right there is hard to see
41:08let me get a
41:11mirror
41:20bam that's looking good right let me
41:23verify this shaft number looking good
41:29and them are looking good
41:34okay all the teacher what I'm what I'm
41:36looking for there is let me get
41:38something to point at with
41:40here okay what I'm looking for you see
41:43these
41:44two dogs cogs whatever you want to call
41:47them I'm checking the very edge of them
41:49they like to round off if you shift
41:53poorly or if it's popped out of gear so
41:55I'm making sure both sides still have
41:57sharp edges and they do um and then same
42:01thing in
42:02here uh let me get you up in here a
42:05little bit
42:07better yeah you can see there okay in
42:10here we have the same thing these little
42:14Nubs right here but on them they go up
42:17into a groov in here I'm looking to make
42:19sure there's no wear up in there they
42:21still has sharp edges and also these
42:23twoo everything looks to be good so I'm
42:27going to assume it's good uh another tip
42:30that you can do is just pull out a shift
42:37fork and look for wear anytime a trans a
42:42gear is jumped out it will leave wear
42:46down here at the bottom as it jumped out
42:48of gear so that's another little tip for
42:52you if if you want it to uh really dig
42:55in deep I'm not not going to worry about
42:56these I can already tell this
42:57transmission's in great shape but
43:01um let me go ahe and pull
43:07this pull that back on out of
43:10there I guess for video sake I will take
43:12a peek just for you guys I'll pull this
43:16shift the uh pen out here slide this
43:21shift Fork
43:23out okay right there you see that tiny
43:27little shiny spot right there that I'm
43:30not going to say that's bad that can
43:32sometimes be totally normal but that was
43:34a tough shift he he kind of forced it
43:36into gear there one time but when you
43:38see it it deep all the way across here
43:42real deep then you know you have a
43:44problem but because I see that there I
43:47will check the gears for that one when I
43:49put it back together I'll take a second
43:50look at it I'm going to pull the bottom
43:52one out
43:55here
43:58just like that you see right there a
44:00little like that can be
44:02acceptable it just means he did a pretty
44:05pretty harsh shift doesn't mean he
44:07damaged anything but if you see a lot of
44:09that then you you pretty much can assume
44:12that that thing is jumped out of gear if
44:14it just really Cuts in
44:16there oh let me get the other get the
44:18other shift fork in
44:25there
44:27I'll explain more of this most likely in
44:29the next video with the KTM 450 where
44:31that one is jumping out of fifth gear
44:34I'll give you a better idea what's going
44:35on there but since we saw that both of
44:37these had the slightest witness Mark
44:40what I would consider a a acceptable
44:42witness Mark I'm going to uh take a
44:46better look at
44:51them of course I'm going have to get my
44:53better glasses too dang it I don't like
44:56wearing these more powerful glasses
44:57unless I have to because then everything
45:00looks funny when I take them off yeah
45:02this is perfectly sharp edge this is
45:06good let me check the one back here uh
45:10which which side was it I'll just check
45:13both sides what the
45:21heck it's looking good there let me get
45:23my mirror
45:24again
45:26like I said that mild amount that I saw
45:29there that's
45:31acceptable that usually just indicates
45:33that they kind of Rush the shift under
45:35power but and some Riders especially at
45:38the pro level they have a tendency to do
45:39that like every freaking lap you know
45:42after a while you'll pay a price for it
45:45but um you get away with it for quite a
45:47while okay I can see
45:54now
45:59yeah everything's good all right I'm
46:02just going to call that um just normal
46:04normal wear but not nothing nothing that
46:06really needs to be addressed he just
46:08forced a shift at one point pretty
46:12pretty harsh but uh it didn't do any
46:14damage to the gears like I said you can
46:16get away with that for quite a while but
46:17I can tell when you've been doing that
46:19cuz I'm going to see stuff like that
46:20when I go in your motor but that's okay
46:23they're racing this bike so we expect
46:25that kind of stuff
46:26happen when you raceing a bike I mean
46:28sometimes you just got to get that shift
46:30in as quick as you can you have no time
46:32to mess around you worry about the
46:34broken stuff
46:36later okay again I'm going to leave that
46:39transmission in place it has been
46:42inspected and it is good oh one more
46:45thing I'm going to take a look at all
46:47the actual teeth themselves not only the
46:49cogs and dogs but also the teeth just
46:52make sure we don't have any Chi Corners
46:53so I'm going to SPS spend the
46:54transmission and watch one gear at a
46:57time okay that's good I'm going to go to
46:59next
47:02one and next
47:05one I'm going to do that to all of them
47:08so I'll be right back everything's
47:10looking good and also this is that's the
47:12beauty of running a magnetic drain plug
47:15is a magnetic drain plug will um if you
47:17ever chip off a corner of a tooth or
47:19anything like that or anything starts
47:20going south in the transmission but the
47:23but the bike still feels fine it's still
47:25shifting through all gears and and you
47:27would never guess that there was an
47:29issue actually starting to happen well
47:31you'll catch it on your next oil change
47:35because you will see it stuck to the
47:38magnetic drain plug I had a
47:42YZ uh let me see if I got a drain plug
47:44over
47:46here that's not the same size I don't
47:52think huh let me go check see what I
47:55have
47:56brand new magnetic drain plug right from
47:58Tusk they're only like
47:59$10 but anyway I had a YZ
48:02450 and I thought everything was fine I
48:05went to go drain my oil one
48:07day and I saw the corner one of these
48:10teeth right here stuck to the magnetic
48:13drain plug it was a Friday I was
48:15planning on riding that bike that
48:17weekend but I didn't when I when I went
48:20to go change the oil on Friday getting
48:22it ready for Saturday and I seen that
48:26um I boarded Mission a rod in that bike
48:29that weekend and took out the YZ 252
48:34stroke and then on Monday I was opening
48:37that motor up and I found the damage two
48:41on the on the transmission and I dressed
48:49that there we go all right now he has a
48:53magnetic drain plug and another
48:55beautiful thing about magnetic drain
48:57plugs is Transmissions are what I'm
48:59doing right here is just clean off the
49:00yamabond anyway Transmissions are always
49:04shedding just fine metal but it happens
49:06they're always shedding stuff and um the
49:09magnetic drain plug will catch
49:12that and it's good to catch that stuff
49:14before it makes it to your piston
49:15because then it can just leave little
49:16scratches on on your piston underneath
49:19the underneath the
49:21uh the compression ring we're going to
49:24clean this case by the way I just want
49:26to get all the Yama Bond off
49:31first yeah the magnetic drain plug will
49:33catch that hopefully before it makes it
49:35to the
49:36piston and it'll get it'll even collect
49:38the very microscopic
49:41shavings that um that can actually make
49:43it through the oil filter they're just
49:45so small so often times when you go to
49:47change your oil and you have a magnetic
49:49drain plug you're going to see some some
49:51dust some metal dust stuck to the magnet
49:55that's perfect perfectly normal that's
49:56just normal wear on the transmission
49:59every time you shift they kind of and
50:00just gears they just they're always
50:02shedding something but you shouldn't
50:04find anything of real size it should
50:08just be like dust as long as it's dust
50:11you're fine clean it off continue
50:13changing oil and take the bike out but
50:15if you find a chunk don't take the don't
50:17take it back out open the motor see what
50:20you
50:22got what I'm doing is just using
50:24something plastic here it works real
50:26good at pulling this yamama Bond off all
50:28the sharp
50:30edges let me finish this up and I'll be
50:32right back okay on the other case now
50:35now this crank is trash as you know the
50:37Rod's bent um I'm going to attempt to
50:40just tap it out with a hammer if for
50:43some reason it doesn't want to come out
50:44I will go up to the press and get it out
50:47that way but let me go ahead and bottom
50:49this out
50:54first grab a 17 mm
50:58socket and grab my
51:01hammer let's see if we get lucky
51:05here it's in there pretty
51:11tight let me leave that in there
51:13actually no I don't need to I'm just
51:14going
51:16to I'll take it to the Press let's go to
51:19the Press real
51:21quick now I understand most people don't
51:24have a press at home so if you don't
51:26have a press at home this happens to you
51:27you can take a torch and heat the
51:30bearing race right here so it expand
51:33loosen up and then hit it with a hammer
51:35again like the way I was doing with a
51:36nut bottom out all the way down and then
51:39a socket on the end or you can take the
51:41whole case put in the oven get it to
51:43about 170° and do the same thing put a a
51:47nut on there socket and hit it with the
51:49hammer and it it will come out don't
51:50worry but since I do have a press here
51:53might as well use the Press
51:57let's do
51:59it I'm put my hand underneath the trank
52:01obviously you don't want it falling
52:04there's still part I need to get out of
52:09it you notice I'm I'm using wood
52:11underneath the motor to protect it the
52:14cases from any scratches damage or
52:19anything there it
52:24goes
52:35crank is out of there let's go back to
52:37the
52:38bench okay we have to get this little
52:40piece out of the
52:42crankshaft it's where the oil feed is at
52:45there's a little hole right there and
52:46there's a pen in there this little piece
52:48we need that for the new crankshaft I'm
52:50going use a magnet you got to kind of
52:52put it here and just kind of Wiggle
52:54that till that pen comes out you'll see
52:58right there there's a pen now we should
53:00just be able to slide this right on out
53:03there we go we'll be able to put that
53:05into the new crank shaft now that piece
53:08right there so this crank is officially
53:11out of there oh by the way quick
53:16observation I think this crank wasn't
53:18cheed very well and I'll check the true
53:20later on and but you see how clean the
53:23surface is right here it looks normal
53:25you can tell the bearing was on it but
53:27it never moved or anything see on this
53:30side see these black marks that one
53:32right there and these big marks right
53:36here wipe it
53:39up and you can see the scaring right
53:41here it looks like it's been The Baron's
53:43been shifting around on here what causes
53:46that is when the crank is not true when
53:49it shifts around like that cuz when
53:51crank's not true these shafts that one
53:54going that way and this one going that
53:56way it kind of wiggle like that as a
53:59crank spinner real quick and the
54:01bearings are tight so that's what gives
54:04right there the bearing race I can see I
54:06can literally see the scratch
54:09marks get you right up in here right
54:11here right here yeah this Baron was
54:13shifting around here I bet you this
54:15crank was not true I don't have time
54:17right now to check it I'll check it
54:18later and update you guys in the
54:20description of what I found or maybe
54:21I'll even make a video on it but let's
54:23continue on yeah you can also see it
54:26inside the bearing here
54:29too I'm almost for certain this this
54:32crank wasn't true well and I'm not
54:35blaming the factory um it can happen
54:38sometimes you know just how it
54:41goes okay I'm going to do the same thing
54:43in this case just clean off the yamabond
54:45before I take them outside and give them
54:48a good blast job and clean them
54:51up but yeah sometimes cranks can just
54:53come out of true on their own
54:55unfortunately it does
54:57happen I'm thinking that's what happened
54:59with this one
55:01so you know alls well it ends well I
55:03mean I know it's going to cost him a lot
55:05of money to get this thing repaired I
55:07mean you saw the parts it was like
55:10$3,315 were but in the end he's going to
55:13go to Loretta hopefully qualifies and
55:16makes it Loretta and he's going to have
55:18a good motor with a good trud crank and
55:21uh blueprinted well and done well
55:25no stones on
55:28turn unless we have some freak accident
55:32or some Act of God this thing should be
55:35solid for 50 hours at least until he's
55:39due for the next top
55:41end and uh well I will say we will be
55:45rechecking the valves cuz these are new
55:47valves they're going to break in so
55:51after a couple weekends of riding we'll
55:53recheck the valves and see if they uh
55:55need any adjustments from there but all
55:58right let me clean this stuff off and
55:59get it cleaned up then we got to swap
56:01out these crank baronss oh and I want to
56:03address this too I don't think it was
56:06the Piston hitting the valves and
56:09bending the rod that put them marks and
56:11on the bearing and on the crank because
56:14that doesn't happen that fast it has to
56:16run a while to leave them type of marks
56:19so and as soon as the Piston hit them
56:22valves the motor locked up right yeah we
56:25were able to turn it by hand because it
56:26locked up in the air he landed with it
56:29locked up and then it broke the motor
56:30free when he landed uh the force on the
56:33rear wheel basically forced the Piston a
56:36hole in the Piston from the valve and
56:38broke the motor free and it lost
56:40compression and all
56:41that but that still wasn't enough to do
56:44that type of wear that we were seeing in
56:46there and scaring witness marks that we
56:48were seeing in there that was a TR that
56:51Crank that has most likely been out of
56:53true but but we'll find out later when
56:56we put on the tring
56:57stand okay okay now I'll take a brand
57:01new box cutter
57:02blade and I'll just run it across all
57:05the surfaces make sure I got all the
57:07yamama bond off I already got it off all
57:09the edges but now I'm just making sure
57:12it's off the flat surface here I can see
57:15a little yamabond dust kicking up as I
57:17go along see that little line there so
57:20I'll make a couple rounds like this and
57:22just again it needs to be a brand new
57:24blade don't use the old one and if it's
57:26starting to snag and catch you Lo them
57:29just flip it over cuz they have one Edge
57:31that's angled towards one side and you
57:33want to
57:35catch they the way they're cut they have
57:37one the the sharp edge usually uh angles
57:41one way or the other you want to have it
57:44that way on the surface so imagine
57:47angled that way and then you want it
57:49like this on the surface that way it
57:52doesn't catch and grab because if I flip
57:54it over over it's going to start
57:57grabbing anyway let me finish this up
58:00I'm also going to go ahead and remove
58:01that sleeve right
58:05there and do the same thing this case
58:08the razor
58:09blade okay let me take these outside and
58:12clean them up all I'm going to do is
58:13just blast them soak them with WD40 and
58:16take a high pressure air
58:18here and just blow them out just blow
58:22everything off of it I'll be back
58:25okay time to start working on these
58:27crank bearings now yeah let me get
58:29something to point with here you'll
58:30notice they have a little like hole
58:34dimple whatever just right in here
58:37that's for you to actually punch this
58:40bolt right here to lock it in there and
58:42usually from the factory I find that
58:44they do that but this one they didn't
58:45for some reason I'm not sure
58:48why but we'll do that when we put it
58:50back together this is a t40 Torx by the
58:53way
58:58they at least had lock tight on it so
59:00that's
59:09good see that's what I was talking about
59:11that little spot right
59:13there but I'll show you better when it's
59:15time to put it
59:19together let me get the other case
59:22now okay
59:34there we
59:34go let me blow the lock TI out of
59:40these and of course I'll give these
59:42these cases another blow job before we
59:44put them back
59:52together okay we got to get the the
59:54crank bearings out of there now there's
59:56two ways to do this I'll show you on
59:58this case right here for you guys that
59:59don't have a case splitter at home um if
1:00:02you set these cases in in an oven at
1:00:05about 170° just set your oven to 170° or
1:00:09if you're using a if you're using a
1:00:10grill
1:00:12outside um then I would at least suggest
1:00:15having one of these things and you can
1:00:16keep track of the temperature of the
1:00:19cases but get them up to about
1:00:22170° cuz that you know we still have a
1:00:24couple rubber seals on this motor right
1:00:28that we're not replacing and they're all
1:00:30seals that we can access from outside
1:00:32the motor if we had to we wouldn't have
1:00:34to pull the motor um but you don't want
1:00:36to damage them and at 170° well it won't
1:00:39hurt them the motor gets hotter than
1:00:41that when it's running so it'll be fine
1:00:43but anyway get it to
1:00:47170° and you find the perfect size
1:00:49socket that'll fit this bearing right
1:00:52here and you use a big big ass
1:00:56Hammer like
1:01:00this make sure the surface that you're
1:01:02doing on it's wood or covered with
1:01:05towels and rags and stuff you don't want
1:01:06to damage the cases as you're pounding
1:01:08it and you can just knock them bearings
1:01:10out once the case is nice and hot like
1:01:12that the bearings will knock out pretty
1:01:15easily but we have a press here so I'm
1:01:18just going to use the Press let's go
1:01:21there okay I got it all set up
1:01:26have a socket there pressing a bar piece
1:01:28of wood underneath it
1:01:41see there it
1:01:49goes reenter it here it kind of got off
1:01:53center
1:01:56all
1:01:59right now let me go get the other side
1:02:01of the
1:02:02case this side's going to be a little
1:02:04trickier because I have the transmission
1:02:07there still in place so I pretty much
1:02:10have to keep my
1:02:12hand like this holding all the
1:02:14transmission parts in place as I do
1:02:22this CU I don't want to that stuff
1:02:25falling out then we got to then we got
1:02:27to piece it
1:02:53together
1:02:59there it
1:03:07is and there's the old crank
1:03:10Barn okay I'm going to go put this half
1:03:13in the oven and get it to about
1:03:16170° remember I have the baron in the
1:03:18freezer I don't want to have to use a
1:03:20press to press this Baron in I I don't
1:03:22like to use a press put them in unless
1:03:24that absolutely have to because for some
1:03:26reason if you don't get them perfectly
1:03:28Square when you put them in that press
1:03:30you can damage these surfaces in here
1:03:33and it can it just it's a little in my
1:03:36opinion it's safer to freeze the baron
1:03:38and heat the case and at that point
1:03:40we'll just have to give it Little lu
1:03:41taps with the hammer on the outer edge
1:03:42of the baron and it'll fall right into
1:03:44place let me go Heat this up I'll be
1:03:46right back okay we got a frozen Baron
1:03:49here let me go get the
1:03:51case Okay looks like I got it to 100
1:03:5476 there so let's knock this bearing in
1:03:58where's my
1:04:00hammer got to work quick here
1:04:08um well any debris that might be in
1:04:11there Here We
1:04:17[Laughter]
1:04:21Go There It Is guys that's all you got
1:04:24to do okay I'm going to flip the around
1:04:25make sure I'm going to check right here
1:04:30and right there make sure I definitely
1:04:32got it fully seated which it looks like
1:04:34I did so that's good there okay let me
1:04:37get the other one on the oven here or in
1:04:39the grill and get that one up the
1:04:41temperature while that one's heating up
1:04:43I'll go ahead explain that a little bit
1:04:44better you want to have good hand eye
1:04:46coordination if you're going to do this
1:04:48and I know there's going to be someone
1:04:49in the comments you never hit a bearing
1:04:50with a hammer I get that every time I do
1:04:52this and you know
1:04:56just don't hit it with the hammer if you
1:04:57don't believe in doing that I have good
1:04:59hand eye coordination you'll see that I
1:05:01didn't hit any of the case anywhere all
1:05:04the way around here all I did was hit
1:05:06the outer um ring the outer race of this
1:05:11bearon you want to avoid hitting the
1:05:12inner race for obvious reasons just hit
1:05:14the outer race and because it's frozen
1:05:17and the case is hot it doesn't take a
1:05:19lot of force these are I'm look how
1:05:21small of a hammer I'm using here I
1:05:22seriously they're just glove TAPS in my
1:05:25opinion again this is safer than using a
1:05:27press and that's why I prefer to do it
1:05:29this way even though I have a press here
1:05:31but te your own if if you want to do it
1:05:32your way that's fine there's nothing
1:05:33wrong with that this is just how I do it
1:05:36and for you guys at home if you want to
1:05:38do it this way it it works again you
1:05:41don't want to go hitting everything and
1:05:42messing everything up make sure you have
1:05:44a little bit of hand eye coordination
1:05:46you definitely want a hammer that has a
1:05:47smooth head on it like that you don't
1:05:48want one of them hammers that have the
1:05:50the nled ends you know but these outter
1:05:53rases are are so the bearings are so
1:05:55tough look can you tell me any spot on
1:05:58that bearon let me zoom in here where
1:06:01you can tell where I hit it with a
1:06:02hammer I bet you can't tell anywhere
1:06:04that's just grease right there I bet you
1:06:06can't tell why because they're that
1:06:08strong you're not going to the the worst
1:06:10thing you can do to these bearings
1:06:12you're not going to like Dent them you
1:06:13can crack them you can break them that's
1:06:16not going to break them what I just did
1:06:18there they don't they don't wear really
1:06:21I mean they do but it takes a long time
1:06:23but they don't Dent that's really strong
1:06:25metal you're not going to knock it out
1:06:26of out of shape or whatever by tapping
1:06:29them in anyway the other one's heating
1:06:31up let me go get that one and get the
1:06:33cold bearing and we'll knock that one in
1:06:35okay got to work fast it's
1:06:38hot this one I have to do a little
1:06:40differently I have
1:06:43to the edge of the bench here let me
1:06:46hold it up like
1:06:48that of course make sure you put the
1:06:50baron in the correct way there's a lip
1:06:53to it
1:06:59[Music]
1:07:06there we go okay so this is when you
1:07:09choose to come here and make all this
1:07:10noise right when I'm doing like the the
1:07:13sketchiest part of the job all
1:07:16right what are you going to do you going
1:07:18to attack
1:07:19me I know you want
1:07:22to acting like you're eating you are not
1:07:24eating you're trying to sneak up on me
1:07:26is what you're trying to
1:07:30do and same thing I'm going to turn the
1:07:32crank around or the cakes around just
1:07:35verify that it got up all the way in its
1:07:38seat and make sure I didn't lose any
1:07:40bearings too sometimes when you heat
1:07:42them up some of these bearings can just
1:07:43fall right out because of the heat so
1:07:46make sure you didn't lose any in your
1:07:47grill or your oven woo the case is still
1:07:49hot all I'm going to let this stuff cool
1:07:51down for a little bit and uh then we're
1:07:52going to slide the crank in there there
1:07:54oops here I am getting ahead of myself I
1:07:57still need to put these things back
1:08:01on lock tight red lock
1:08:06tight that's what you're going to want
1:08:07to use on these bad
1:08:12boys and we're going to punch them in
1:08:19too
1:08:22right
1:08:26luckily whoa let me clean that one to
1:08:30relock tight it right back okay here we
1:08:50go going to use an impact like I did
1:08:54be familiar with your impact that's
1:08:56setting number one that I used right
1:08:59there which is a really light
1:09:02setting now not only do we have lock
1:09:04tide on but I'm going to do what they
1:09:06seem to miss from the factory take a
1:09:08nice pointy punch
1:09:16here there we
1:09:22go
1:09:28there we go and this is why I call this
1:09:31Blueprinting we're basically making sure
1:09:33everything is right from the crank being
1:09:35true to making sure the manifold on the
1:09:38head is perfectly centered out to making
1:09:41sure none of that stuff was missed out
1:09:43right there let me show you how that
1:09:45looks see you just hit the corner into
1:09:47that Groove and that'll keep it from
1:09:49spinning loose right there and I'm going
1:09:52to do the other side and I'm going to
1:09:53use I'm sorry thread Locker not Loctite
1:09:56thread Locker this will be the last time
1:09:58I ever buy Loctite I'm going to use this
1:10:00stuff up be done with it and I'm going
1:10:01to find another brand
1:10:04because well they're four closing down
1:10:07riding areas you know obviously they say
1:10:10it's for environmental reasons but yeah
1:10:12you know we got to live our life it
1:10:15seems like every time something's for
1:10:16environmental reasons they're actually
1:10:18just taking it away from us and then
1:10:19then the government owns it and has all
1:10:21the authority over it and we don't have
1:10:23any anymore anyway let me go put these
1:10:27in okie dokie a frozen crank don't drop
1:10:30it if I drop it I'll be TR
1:10:34it okay there's no rubber seals on the
1:10:37other side of this or anything
1:10:39so at least let me double check yep okay
1:10:42what I'm going to do is I'm going to
1:10:43heat up the inner race here now you
1:10:45don't want to get it all blue you don't
1:10:48want to get it that hot just just get
1:10:51some temperature in it and that that
1:10:52Frozen crank it's going to slide right
1:10:55on in and you want to rotate around it
1:10:57like I'm doing here so you don't create
1:11:00a hot spot kind of distribute the heat
1:11:03of course make sure you put the crank in
1:11:04the correct way right I know the Stater
1:11:07side is on the other side so let's see
1:11:08if I can get it in yet let's see
1:11:13here all right that's the Stater side on
1:11:16this side so and that's the side okay
1:11:18yep
1:11:20y there we go um I'm going to sit here
1:11:24and hold it for a minute because it'll
1:11:25equalize in temperature and lock in um
1:11:29I'm putting it on the same side as a
1:11:31transmission I know it came apart
1:11:33opposite of that but I like to put it
1:11:35together like that because at that point
1:11:37the other side of the case over there is
1:11:38just going to be like a cap we're just
1:11:40going to pop that sucker right
1:11:44on we're getting really really close to
1:11:47put these cases
1:11:49together okay I'm going to give this
1:11:51side a nice little blow job to get the
1:11:53w40 that kind of settled to the bottom
1:11:55there out of
1:11:58there I don't want that to interfere
1:12:01with the yamama
1:12:03bomb I mean y yamama bomb is pretty
1:12:05resistant to
1:12:07oil but just be
1:12:11safe now I'm going to blast in each one
1:12:13of the threads in case there's any grit
1:12:15or anything in there I want to get all
1:12:17that out of
1:12:19there or y a bond that might be sitting
1:12:22in there whatever
1:12:30okay then I'll take some brake
1:12:35cleaner put some on a rag and go around
1:12:39the surface that we're going to be
1:12:40putting the yamama bond
1:12:43on just to get rid of any excess oil
1:12:46oils that might be on it again yamabond
1:12:50is very resistant to um pondon yamabond
1:12:54Moto seal whatever it's all the same
1:12:56stuff very resistant to
1:12:59oil and before I forget remember that
1:13:01little pile back here I said I have to
1:13:03make sure this stuff is on the motor
1:13:05before I put the motor
1:13:13together and that I have the r written
1:13:16right there so that goes on the right
1:13:21case there we go
1:13:24and same
1:13:36thing it's looking
1:13:39good take some brake cleaner clean that
1:13:52surface
1:13:59all right I'm going lay a piece of
1:14:01cardboard down here now so we Slide the
1:14:03cases together no cloth gets stuck up in
1:14:06there all right let me grab the I'm aond
1:14:10okay I'm going to be using actually I'll
1:14:12be using Moto seal from permex Moto seal
1:14:17uh this is good stuff right here it's
1:14:19the same stuff as yamabond Honda Bond
1:14:21all that kind of stuff heck they even
1:14:23gave the name Moto seal that should let
1:14:25you know right there okay I'm going to
1:14:27put a thin
1:14:29layer all the way
1:14:34around we're going to have to work quick
1:14:36here this stuff only gives you about 10
1:14:39minutes to work with it so you want to
1:14:41move
1:14:51fast I'll be right back
1:14:53okay as I put on my gloves here I'll
1:14:56just um let you look at that for a
1:14:58minute and see all the places that I put
1:15:00the yamama bond basically I went around
1:15:04that all around all these outer edges
1:15:06and all the circles all the way around
1:15:08the outer edge I'm double checking it
1:15:11too as I show you where I put it make
1:15:14sure I didn't miss a spot go back
1:15:17through one more time um from the
1:15:19factory I don't know why they put some
1:15:21here so I went ahead and put some there
1:15:23I don't know why because that's just a
1:15:24thread um for that little Center engine
1:15:28bolt case so I don't know why they put
1:15:30that
1:15:32there oh I know why so oil doesn't leak
1:15:35out of the bolt they could have put a
1:15:37copper washer but maybe that's cheaper
1:15:39than a copper washer I guess now one
1:15:41area I do like to put it that they
1:15:42didn't is this little area right here
1:15:44that's where the oil pickup is at some
1:15:47people might say well you don't want to
1:15:48do that because if it breaks off it
1:15:50might get in an oil pump but no they
1:15:52have this screen here right before the
1:15:53oil pump goes in there it it'll be seen
1:15:55on that it'll get caught on that before
1:15:56it goes in the oil pump so it'll be fine
1:15:58plus you have to consider if that if
1:15:59you're worried about that then you have
1:16:00to worry about all of this this going to
1:16:02all break off and go up there and go in
1:16:04the oil pump I like to do that right
1:16:06there to guarantee it's getting a fresh
1:16:08shot of oil from the bottom with no air
1:16:11mixed with it it's just something I do
1:16:13they don't do that from the factory for
1:16:14whatever reason or at least they didn't
1:16:15on this motor I've seen some Motors they
1:16:18do some they don't I don't
1:16:21understand okay let me find some way
1:16:23prop this up so we can heat up that
1:16:26bearing so it'll slide right on the
1:16:30case um actually let me let me do
1:16:33something here real
1:16:35quick yeah I'll just do it like that
1:16:39okay guys here we
1:16:42go got to be honest this is this is the
1:16:44more nerve-wracking part of the job for
1:16:48me same thing heat up and Sh my light so
1:16:50I can see the Flames going it's the more
1:16:53nerve-wracking part of the job for me
1:16:54because you have to work quick with
1:16:57yamabond and everything like that and if
1:16:59you make a mistake you got to take it
1:17:01back apart and clean up that yamabond
1:17:03when the yamama Bond's not completely
1:17:05dry it's all gooey and it's just it's
1:17:07hard to get clean it up that way it's
1:17:09better to clean up when it's fully
1:17:12dry I'm going to get some heat on this
1:17:14Baron so it slides right on that crank
1:17:16so we don't have to force anything we
1:17:18not we're not going to have to pound it
1:17:20or anything like that and same thing as
1:17:22the other bear and few circles I'll get
1:17:24a little bit more heat in this bearing
1:17:26because I want one shot when I did the
1:17:28crank earlier if the crank didn't slide
1:17:29on I could have I could have just uh get
1:17:31put more heat on it this one we get one
1:17:33shot at
1:17:40it okay there we
1:17:45go all right turn my light back on set
1:17:49that right there set this right here
1:17:52let's transmission's nice and neutral
1:17:54make sure the shift Fork pens are down
1:17:57all the way in their hole yes they are
1:18:00transmission's fully seated yes it is
1:18:03okay here we go set that right on my
1:18:08gut here we
1:18:19go there's that shaft right there
1:18:21binding this up that's okay it's
1:18:25together
1:18:27okay yeah it's just a shaft in there
1:18:29it's a little tight going in that
1:18:30bearing if I didn't have that seal in
1:18:32there um I can heat that bearon up too
1:18:34and then it makes it literally just drop
1:18:37right in but we're not looking to
1:18:39replace that seal we're look and uh we
1:18:41can always replace that from the outside
1:18:43of the motor if it ever started leaking
1:18:45so we're not worried about that
1:18:50one figure out some way to prop this
1:18:52motor up up there we
1:18:55go trying to work quick here before the
1:18:58yamabond
1:19:00dries okay got to put these bolts
1:19:04in how do you know which bolts go in
1:19:06what hole right well they should all
1:19:09stick out an equal
1:19:11amount this one's nice and shiny this
1:19:13one tells me that one went
1:19:16there they should all stick out an equal
1:19:19amount when you have them in the correct
1:19:20holes that one's dirty I remember that
1:19:23one went right
1:19:30there that one's too
1:19:33long there we
1:19:35go there we
1:19:37go got another long one
1:19:42here right
1:19:44there and there and there okay you know
1:19:48when you have them all in the correct
1:19:49hole like I said they all stick out
1:19:50about 11 or 12 mm I don't know exactly
1:19:53how much but as long as they all is all
1:19:55they're all sticking out equally you
1:19:57know you have them in their correct
1:19:59home so let's go ahead and tighten them
1:20:02up I'm just going to use this cordless
1:20:05impact through the do the twisting force
1:20:07for me I'm first going to tighten up
1:20:09around the crank
1:20:12[Applause]
1:20:21shaft
1:20:24[Music]
1:20:38[Applause]
1:20:40[Music]
1:20:45now I'll tighten them by
1:20:51hand
1:21:07I'm going to tighten it in stages the
1:21:09first I just kind of go around and
1:21:11bottom them out pretty
1:21:14good CU as we're doing this we're kind
1:21:16of squeezing the yamama bond out of the
1:21:19edge out between the cases
1:21:28there are torque specs for this if you
1:21:30want to follow the torque specs I've
1:21:31been doing this my whole life so I have
1:21:34a calibrated
1:21:37hand but for you guys that aren't
1:21:39breaking out torque wrench these are
1:21:41easy to strip out so don't go crazy wait
1:21:44you just bottom them out and snug them
1:21:46up pretty dang good
1:21:51okay
1:22:21for there we
1:22:24go make sure the transmission spins nice
1:22:27and freely yes it does and it's still
1:22:29neutral I can shift I can spin both of
1:22:31these shafts independently of each other
1:22:34make sure the crank spins it nice and
1:22:35smoothly yes it
1:22:37does got some yamama pond on it right
1:22:40there and lastly make sure the counter
1:22:42balancer over here shaft spins nice and
1:22:45freely yes it does we're good let me
1:22:49wipe this up right here make it a little
1:22:51prettier
1:22:55and wipe it up right here where it meets
1:22:57the
1:22:58uh the
1:23:08cylinder okay now the crank was cold
1:23:11right so it's going to sweat let me go
1:23:13get some gy 40 and just lather it
1:23:21up
1:23:27there we
1:23:29go and then what I'll do is I'll just
1:23:31take the
1:23:33motor flip it over for a minute and let
1:23:36that let that drain out of there real
1:23:40quick okay let me go ahead and put this
1:23:42thing back in take the gloves off these
1:23:45gloves are getting a little
1:23:50dirty basically that hole right there
1:23:53this pin goes through
1:24:01it here we
1:24:03go use a piece of safety wire get that
1:24:06pin all the way in there so it doesn't
1:24:08get in my way during assembly once you
1:24:11have the gears on here it'll lock that
1:24:12pen from slipping out of there but even
1:24:15while we're working on it the spring
1:24:16pressure right now against it holds it
1:24:18in place so we'll be
1:24:20good Everything feels good all right
1:24:23right okay I'm just going to reverse the
1:24:26order that I pulled everything
1:24:30apart this was my bundle that goes on
1:24:33top of the crank here but if you
1:24:35remember we have to put that gear on
1:24:36first before we put the oil pump
1:24:41on so let me cut
1:24:51this
1:24:53wipe that up so I can see it there's a
1:24:56DOT right there dot dot goes where that
1:25:00little where we slid that little pen
1:25:04in there we
1:25:07go now that that is on we can go ahead
1:25:10and put the oil pump back
1:25:15in I'm just going to put some assembly
1:25:18Lube up in the oil pump right here since
1:25:21we did have it a part don't need to go
1:25:23crazy with it just a little Lube until
1:25:25trust me it's going to suck up oil right
1:25:36away okay let's pop this
1:25:43on oh Pop back off I see a piece of
1:25:46cloth right there there we go double
1:25:49check that it's
1:25:51clean
1:25:54and lock tight as I'm sorry thread
1:25:57Locker as always dang I got to get out
1:25:59of that
1:26:00habit the red stuff you want the red
1:26:03stuff inside of these motors don't be
1:26:05fooling around with the blue stuff in
1:26:21there
1:26:29[Music]
1:26:33I already put that Rubber seal back in
1:26:35there by the way once I realized I was
1:26:37pulling it off I was like might as well
1:26:38stick it on now same thing don't
1:26:41overtighten these don't strip them out
1:26:42bottom bottom them out and just snug
1:26:45them up against that wall it's all you
1:26:47got to
1:26:49do once you feel it takes a whole lot
1:26:52lot more pressure to get even a crack
1:26:54more out of it you better stop right
1:26:57there okay let's continue on with these
1:26:59crank gears
1:27:08here this one can go on
1:27:12anyway I'm just going to put this on
1:27:13fingertight for right now we're going to
1:27:15locktite all that in we're going to pull
1:27:16it back off and lock tight it in place
1:27:19in a
1:27:20minute after I put the counter B your
1:27:22stuff
1:27:27on okay first goes that washer or
1:27:33spacer this gear right here it has a DOT
1:27:36right there that dot lines
1:27:39up on one of these splines
1:27:42here which one is
1:27:51it
1:27:52oh you know what it doesn't matter see
1:27:54how this no it does
1:27:58matter I'm just going to try I'm not
1:28:01seeing where it's supposed to
1:28:03go with my naked eye
1:28:08here let me oh I see it right there
1:28:10there is one there's one of these
1:28:13splines that's a low cut that's where it
1:28:17goes the dot goes with the spline with
1:28:20the low
1:28:21cut
1:28:22okay I got it with that but remember now
1:28:24we have another dot it's right there and
1:28:26has to line up let me line it up first
1:28:29and I'll show you closer with the camera
1:28:32with the dot on the
1:28:35crank this thing get stuck up in
1:28:41there there we go all right let me get
1:28:44you up in here and show
1:28:47you that dot lines with that dot and
1:28:50this dot lines with the SP line that is
1:28:53shorter than the other splines in this
1:28:54shaft and that will properly time in
1:28:58your counter
1:29:00balancer lock tight I mean thread Locker
1:29:04thread Locker time all right get it
1:29:10right they don't use thread Locker on
1:29:12these from the factory because they have
1:29:14them washers that are kind of
1:29:16like concave or whatever and that's
1:29:19supposed to keep these things from
1:29:20spinning loose but
1:29:23yeah not me
1:29:25man I'm using
1:29:35locktite
1:29:37okay okay in the manual there are torque
1:29:40specs for these things and you can
1:29:41follow that if you like uh the best way
1:29:43to keep the motor from spinning is to
1:29:45put the clutch Hub back on stick a piece
1:29:46of aluminum in these gears so it can't
1:29:49spend by hand and then you can torque it
1:29:51down that motion Pro sells a little gear
1:29:53thing that can fit in there and hold it
1:29:54but as long as you got a slab of
1:29:56aluminum um just any kind of aluminum
1:29:58like this right
1:30:01here anything like one of these old you
1:30:04can you can stick it right between the
1:30:05teeth and that do the trick I'm using
1:30:08impact I'm familiar with my impact I
1:30:10generally know how much force is putting
1:30:12down I'm going to start on setting
1:30:13number one I'm going to hold the rod
1:30:14here so it don't
1:30:20spin
1:30:25there we go that one's bottomed out
1:30:27right here same
1:30:35thing okay and then what I'm going to do
1:30:38for my impact again you need to be
1:30:40familiar with your impact if you're
1:30:41going to use impact I'm going to put on
1:30:43setting number two and just give each
1:30:44one a super quick
1:30:50wrap that's that's
1:30:56it verify again that these are lined up
1:30:58yes they are Everything feels
1:31:03good okay what's next what's next H oh
1:31:09let go put the shift shaft back in
1:31:19here I should have did this in minut AG
1:31:22go I need to verify that's it's going to
1:31:24shift through all its gears I forgot to
1:31:26check that we know it's a neutral that's
1:31:28use it good indicator you got it right
1:31:30honestly if if it's a neutral it's
1:31:32usually good but I have seen one time
1:31:36where was a neutral and every gear was
1:31:38good except one so let's do this that's
1:31:41going to be first gear so I spin this
1:31:43shaft I'm feeling this shaft spin so we
1:31:46know we're in first can't go anymore go
1:31:48back to neutral I'm spinning this shaft
1:31:50that one's not spinning second gear
1:31:52sometimes you have to spin the shaft a
1:31:54little bit as you shift the gear no
1:31:55different than you have to roll the bike
1:31:57sometimes when it's off the shift gears
1:31:59because get stuck between two gears
1:32:03there's
1:32:05third
1:32:08fourth fif and let's make sure we didn't
1:32:11end up with the extra gear NOP we're
1:32:17good back in
1:32:20neutral sweet
1:32:22we're good
1:32:23there all righty all righty what's next
1:32:31this now when your engine builder
1:32:34charges you what seems like a ridiculous
1:32:36amount of money to rebuild your
1:32:39motor now you see why it can be very
1:32:41tedious now there are some engine
1:32:43builders just kind of slap them together
1:32:45they don't take this much time and you
1:32:47shouldn't be using someone like that but
1:32:51if you're using a good engine builder
1:32:52and they're charging you um a fair
1:32:56amount understand it's
1:32:59work and it it's a lot of responsibility
1:33:02too because you have to make sure
1:33:04everything is
1:33:08right and if something goes wrong well
1:33:10they're going to be pointing the finger
1:33:11at you it is a lot of
1:33:16responsibility Now understand these
1:33:19bikes don't come with a warranty when
1:33:20they're brand new well the Y I think
1:33:22they come with like one month warrant
1:33:23warranty on the motor now but only the
1:33:25motor and even then it's hard to get
1:33:27them so I saw to put the washer there
1:33:29spacer and even then it's hard to get
1:33:32them to honor it I'm going to slide this
1:33:35on actually let me just pull all this
1:33:40out there's a washer right here on this
1:33:42thing there it is that was getting in
1:33:45our way but that's okay we got to put
1:33:47all these clutches back on
1:33:49anyway there we go
1:33:53it's like a one month warranty on the
1:33:54Yamaha motor brand new um but it's
1:33:58really hard to get them to cover it and
1:34:00it's only for like catastrophic weird
1:34:02type
1:34:03stuff but typically most bikes don't
1:34:05come with a warranty when it's brand new
1:34:07and for good reason they're race bikes
1:34:09they know we're going to go out and beat
1:34:10the crap out of them keep in mind
1:34:12anything can happen right I've seen
1:34:14brand new Motors blow cranks stuff like
1:34:16that so if your engine builder put your
1:34:18motor together and he did a good job and
1:34:20something went South pretty early don't
1:34:22just automatically blame him understand
1:34:25I'm pulling these clutches out right
1:34:26here we're going to put them in
1:34:27understand sometimes Parts just fail um
1:34:31okay we're going to start one fiber oh
1:34:33getting ahead of myself here we got that
1:34:36washer on
1:34:40okay all right one
1:34:42Fiber One steel but remember I said the
1:34:45round edge here goes towards the
1:34:49motor one fiber
1:34:52one steel and he had all these
1:34:56backwards looks like on
1:34:59Fiber One
1:35:02steel one
1:35:07Fiber One
1:35:11steel looks like I'm have to flip all
1:35:13these
1:35:20around
1:35:28there we
1:35:29go yeah I heard one engine builder for a
1:35:32professional race team say um when he
1:35:35was asked if they replace every part
1:35:36inside the motor after every race can to
1:35:40use thread Locker in this um he said no
1:35:43he said there are some parts that he
1:35:45that they consider proven
1:35:47Parts you know certain things like maybe
1:35:49the inside of this Hub right here
1:35:51counter balancer shaft all that stuff
1:35:52they're proven Parts you can inspect
1:35:54them visually you can see they're good
1:35:56but they proven not to be a dud and that
1:35:59that's the point Sometimes some parts
1:36:01can be Duds it
1:36:04happens it's rare but it happens so have
1:36:07mercy on your engine builder is what I'm
1:36:09trying to
1:36:14say cuz trust me anything goes wrong
1:36:16with the bike we're the first ones that
1:36:19hear about
1:36:20it and it's
1:36:22usually initially blamed on us till we
1:36:24can prove
1:36:26otherwise same thing I'm going to start
1:36:28on setting number one
1:36:32here we saw we I can see where that
1:36:35punch Mark was all the way over
1:36:38there get a little bit
1:36:42more little
1:36:49more there we go
1:36:51okay I want to verify that the inner
1:36:53moves separate from the outer yes it
1:36:55does so nothing's binded or anything
1:36:57going to knock that piece in
1:37:06there let me knock that back in
1:37:11there there we go and of course that's
1:37:15another little safety tab keep it from
1:37:16coming loose but we also put Loctite on
1:37:20it
1:37:21okay let me just look everything over
1:37:23real good one more time before
1:37:28we remember I had that little ball
1:37:31bearing that goes in
1:37:33there and this goes on top like
1:37:37that light this
1:37:45up make sure it goes all the way onto
1:37:47the plates and it
1:37:50is
1:37:55now I'm not using locktite on these
1:37:58clutch springs because the spring
1:38:01pressure um just acts like its own lock
1:38:04height I've never seen these come loose
1:38:06as long as they're you know torqu down
1:38:08pretty decent they they stay in place
1:38:10that spring pressure really holds them
1:38:11down from coming
1:38:20loose
1:38:22that one's being
1:38:24stubborn let me get a
1:38:26Phillips try to figure this
1:38:31out huh let me look at the threads here
1:38:34make sure threads are good let me blow
1:38:36that
1:38:38out trying not to force
1:38:46anything okay I think I see what's going
1:38:48on I think someone started to cross
1:38:51tried this thing one
1:38:54time let's see if we can get it in
1:39:00there there we go
1:39:06okay all right yeah I know this is a
1:39:08long video but I appreciate you guys
1:39:09coming along for the ride shout out to
1:39:12all you guys out there all over the
1:39:20world
1:39:35I hope you guys are getting something
1:39:36out of this or at least
1:39:40entertained okay now I'm just going to
1:39:42tighten it by hand I'm going to hold the
1:39:44clutch don't go crazy with it you can
1:39:47break them little towers that these
1:39:48things go into you just bottom them out
1:39:51pretty good long as you're holding this
1:39:54by hand like this you really can't get
1:39:55it too tight and choke up on the on the
1:39:59ratchet you'll be fine here we
1:40:07go going to verify my work
1:40:11here let's get something I'm basically
1:40:14going to activate the clutch by hand I
1:40:16want to see that pressure plate come
1:40:18up there it is we're
1:40:26good pop these things back where they
1:40:30go and we'll put the gasket
1:40:33on
1:40:36okay brand new
1:40:41gasket okie
1:40:48dokie let me take one more piece in here
1:40:51make sure that's
1:40:53there OCD in it that's all I'm doing
1:41:03here oops dang
1:41:10it all
1:41:14right I will probably have to spin the
1:41:17crankshaft while I'm sliding place to
1:41:19get the I didn't have to but sometimes
1:41:21you have to spin the crank a little bit
1:41:22to get in place to get the water pump
1:41:24gear to line up with the gear in
1:41:31there but we didn't have to
1:41:36today so today was a good
1:41:41day I believe these are all the same
1:41:44size so you
1:41:45just stick them in all the
1:41:49holes
1:41:51[Music]
1:41:56I'll tighten all these
1:41:58down and I'll tighten them all by
1:42:02hand same thing as I keep saying don't
1:42:05strip them
1:42:16out there we
1:42:18go brand new Yamaha oil
1:42:21the rubber side oh there rubber two
1:42:23sides okay the open end the completely
1:42:25open goes all the way in not this one is
1:42:27closed off but the completely opening
1:42:29goes in
1:42:39first here we
1:42:43go pop these
1:42:49on
1:42:53okay that side's done let's turn around
1:42:55and work on the other side pop this
1:42:58little sucker right in here that little
1:43:00filter here we
1:43:03go I'm going to get it right this time
1:43:06I'm put a dab a thread
1:43:09Locker on
1:43:13there all right tighten that
1:43:16up pop that on
1:43:19there
1:43:21there you
1:43:23go counter
1:43:29balancer that only goes on one way it's
1:43:31got a little cut out some thread
1:43:35Locker as
1:43:38always don't want to take any chances
1:43:48there same thing I'm going to start on
1:43:49setting number one this is a smaller
1:43:52bolt that threads the shaft in the
1:43:54middle that threaded is smaller so you
1:43:56got to be more
1:44:01gentle super quick wrap on number
1:44:04two there we
1:44:07go and I failed to mention I was holding
1:44:09the rod there so the crank doesn't
1:44:13spin new timing chain time
1:44:19Yamaha
1:44:34okay put the tensioner on in there
1:44:37tensioner
1:44:44guide all right some thread
1:44:49Locker
1:45:18little tight here we go
1:45:22all
1:45:28right remember
1:45:31that slide that on right
1:45:37there we're getting there we're getting
1:45:40there this is a long
1:45:48job okay you'll see that there's like
1:45:50metal dust see I'm going to wipe that up
1:45:53real quick so let me clean this
1:45:56up
1:46:06doie got to line it up with that keyway
1:46:09there it
1:46:10is want to verify that's on it by
1:46:12grabbing the rod and try to spend the
1:46:14this separate from that it's Lo it's
1:46:16locked in so we're
1:46:19good and again thread
1:46:23Locker now there are torque specs for
1:46:25this and like I mentioned you can grab
1:46:27it right here with a wrench hold the
1:46:31flywheel and follow the torque
1:46:33specs with the torque wrench put a
1:46:37little
1:46:38more the red Locker on
1:46:43there I don't want anything coming loose
1:46:45in this
1:46:49bike
1:46:51but I'm just going to use the
1:46:59impact and again starting at setting
1:47:02number two one this this impact has
1:47:04three settings by the
1:47:09way and um setting number three is
1:47:12actually pretty powerful this it's a
1:47:13little impact but this sucker it's got
1:47:16some power in setting number
1:47:19three
1:47:22that one's good to go that was setting
1:47:24number two by the
1:47:26way okay we're about to install the
1:47:29um the piston and the cylinder we'll put
1:47:32the cylinder head on while it's on the
1:47:34bike it just makes it easier to get the
1:47:36motor in what I'm doing is I'm cleaning
1:47:38the gasket surface here with a brand new
1:47:41box
1:47:45cutter and from this point on you got to
1:47:47be real careful when you turn the motor
1:47:48by hand you have to hold the timing
1:47:50chain up so it doesn't get kinked up
1:47:52down
1:47:54there okay brand new piston time showing
1:47:57the arrangement of the piston rings
1:47:59right there you can down your download
1:48:02your manual for free um I'll put a link
1:48:05in the description for that actually
1:48:07where Yamaha actually gives them away
1:48:10for free right from Yamaha it's really
1:48:12cool I don't know any other brands that
1:48:14do that actually that that is just a
1:48:17huge um win for Yamaha as far as that's
1:48:21concerned if you own a
1:48:27Yamaha it's nice I know some Brands will
1:48:30give you a a manual for free but it's
1:48:32nice when you have for me I like to have
1:48:34them on the computer myself because I
1:48:36can just have them on my phone like
1:48:46this there we
1:48:49go
1:48:55piston in here need
1:48:58that that is a OEM piston right
1:49:06there
1:49:08okay the first top ring there I'll show
1:49:12you guys one more time the top ring
1:49:14that's your compression ring you see the
1:49:16a has a a right there and a up there it
1:49:19shows where it's supposed to to be of
1:49:20course the dot on the Piston is down
1:49:23there at the bottom you see the dot
1:49:25right here so we're just going to follow
1:49:27that now again people ask um did you
1:49:30check the ring end Gap I'm going to make
1:49:31a whole separate video on ring end gaps
1:49:34and I'll explain to you why it's just
1:49:35not necessary nowadays on these modern
1:49:37day bikes as long as you're running the
1:49:39basically the stock nickel plated
1:49:42cylinder really you think they're
1:49:44checking every ring and GAP going down
1:49:46the assembly
1:49:49line
1:49:53they're
1:49:54not okay we got the top ring in gap in
1:49:58the upper Oil ring the oil ring expander
1:50:01okay the oil ring expander goes right
1:50:02where the dots at I'm going to do that
1:50:04one
1:50:09next there we go make sure it doesn't
1:50:11overlap down
1:50:13here here we go and the top Oil ring
1:50:18that's the the
1:50:21okay that goes just to the right of the
1:50:26dot oh that's not the top that's the
1:50:30bottom yeah if you read the manual just
1:50:33to give you a quick gist it tells you
1:50:35what the ring Gap is supposed to be at
1:50:38but it doesn't mention anything about
1:50:39filing it just tells you how to check it
1:50:42and if it's at a spec replace it doesn't
1:50:44say if it's out of spec too tight file
1:50:46it if it's too loose replace it no it
1:50:48just says if it's out of spec replace it
1:50:51what they're basically saying is there
1:50:54should be no reason to file them they
1:50:55should come and spec right out the
1:51:01box it's old school you know you know
1:51:05having to file them or I will say
1:51:07aftermarket Pistons if you use
1:51:08aftermarket Pistons they usually come
1:51:10with instructions of where you should
1:51:12have it have your ring in gap set and
1:51:14follow that like Wiseco has their own
1:51:16sets of instructions because they're
1:51:17using a different type of piston ring
1:51:19right their own piston rings so follow
1:51:21that but for OEM you just put them on
1:51:24that's all you do just put the rings on
1:51:26and run it it's good there's no filing
1:51:31necessary all right that shifted let me
1:51:33get that oh that belongs up there oh man
1:51:36I was moving so quick I forgot to even
1:51:38mention the compression ring the top
1:51:41ring there's a top and a bottom see that
1:51:44t right there that's indicating that
1:51:48y
1:51:50right there that's indicating top so you
1:51:52want that faced upward it's real
1:51:54important sorry about that just rushing
1:51:57along jabbering along not paying
1:51:59attention Okay that one needs to be off
1:52:01to the side let me see where I have
1:52:02these at okay these are right there
1:52:05that's right of course we're going to
1:52:06check them again once we get on the bike
1:52:07cuz they're going to shift as I'm
1:52:08putting all this stuff
1:52:10together all right I'm going to put one
1:52:12C clip on now before we put it on
1:52:18the there we go
1:52:29okay I'm just going to take the open end
1:52:32right here stick it where the open end
1:52:34is on the
1:52:38piston and work it in all the way around
1:52:40with the Flathead
1:52:44here of course I have the wrist pin in
1:52:46there I'm holding in with my finger that
1:52:47keeps me from just pushing that c clip
1:52:49all all the way through kind
1:52:51of helps line it up in place with the
1:52:54with the seat that it's supposed to go
1:52:55into there we
1:52:57go voila that's perfect I I personally
1:53:01you can do it you can follow the manual
1:53:02the manual says a little bit different
1:53:04the manual says put that open end right
1:53:06over here I like to have it right here
1:53:08with the leave the open end with the
1:53:10open end right there open of the Circ
1:53:12clip with the open end of the Piston
1:53:14that way all the way around it's in a
1:53:16seat and its Groove I've been doing it
1:53:17like that for years no problems but you
1:53:20can do it however you like okay um this
1:53:23dot right here indicates the exhaust
1:53:25side you'll see exhaust valves are
1:53:26smaller intake valves are bigger so and
1:53:29this is a reverse motor so the intake is
1:53:31on the front side of the motor so we got
1:53:33to remember that when we put it on the
1:53:34bike or I mean the motor okay I'm just
1:53:37going to drop a little bit of sim Lube
1:53:39right on the edge of the bearings here
1:53:40there's a little hole on top of the rod
1:53:43and I'll kind of let it use in
1:53:46there just a little bit just so it has a
1:53:49little bit on initial startup don't want
1:53:50to go too crazy with it I don't need
1:53:52that stuff contaminating the motor oil I
1:53:54mean we're going to do a motor oil
1:53:56change shortly after a complete Brak in
1:53:58but
1:53:59still then I'm going to take some and
1:54:02put it in here now that part's pretty
1:54:03important because this is a new um rod
1:54:07and that was bone dry and that can
1:54:10sometimes take a little while before it
1:54:12starts actually receiving engine oil so
1:54:15it's a good idea to get that on
1:54:18there
1:54:20might as well wet this up a little bit
1:54:24too not going crazy with it just uh a
1:54:28little
1:54:29bit all
1:54:42right here we go let me get a clean rag
1:54:46I know some of these Rags don't look
1:54:48clean they've been using million times
1:54:50and washed but they're
1:54:53clean putting this around here so in
1:54:55case that c clip goes flinging off in
1:54:57the outer space we at least know it
1:54:59didn't go in the
1:55:01motor okay you're not going to be able
1:55:03to see me put this one on but I'm
1:55:05putting it on the same way I put the
1:55:06other one
1:55:18on
1:55:25there it is okay now I'm going to let me
1:55:26get my better glasses
1:55:28here I'm going to verify that it's in
1:55:31its seat in its Groove all the way
1:55:33around I'm not going to just assume it
1:55:35is I need to see
1:55:48it
1:55:54it's looking good on this end let me
1:55:55recheck the other
1:56:03end yep it's looking good over
1:56:06here okay the big cutouts are definitely
1:56:10on the intake side small ones are on the
1:56:13exhaust side we know we got that right I
1:56:15know I already said that once but you
1:56:17know what happens is if I don't say that
1:56:19once twice twice three times tonight
1:56:21while I'm laying in bed I like did I put
1:56:23that in right and I'll be sitting out
1:56:25here with a little scope sticking it in
1:56:27the cylinder and see if I got it right
1:56:30so
1:56:35yeah okay cylinder base gasket
1:56:39time brand new right from
1:56:42Yamaha gently put that in there for
1:56:48now
1:56:54make sure the Rings are still in the
1:56:55right spot okay I see that one's there
1:56:58and this one's right here okay let me
1:57:00get the brand new
1:57:01cylinder okay I typically don't oil a
1:57:04piston when I do a top end I don't put
1:57:06any oil on it any some lube anything
1:57:07like that because if you get too much
1:57:09oil all up in them oil rings it will
1:57:11blow smoke for quite a while until the
1:57:13oil rings finally seat it can take quite
1:57:15a while if you're doing this doing this
1:57:17for a customer they come pick up their
1:57:19bike you're like wait why is my um why
1:57:21is my bike smoking I I paid you to do a
1:57:23top end what's going on here so I don't
1:57:26do that and uh but because this is a
1:57:29brand new cylinder with fresh honing all
1:57:31I'm going to do is take some motor oil
1:57:34and just uh just regular motor oil shell
1:57:38Rella 1540 to be exact and I'm going to
1:57:41wet
1:57:41it with the motor oil and then I'm going
1:57:44to wipe out the excess oil so basically
1:57:48it's not not going to be dripping wet
1:57:50you're not even to really be able to see
1:57:51any oil on it but I guarantee you you're
1:57:53not going to want to put your tongue on
1:57:54it there's
1:57:58yeah I'll take a rag and just wipe that
1:58:01oil out of
1:58:02there what I'm really kind of doing here
1:58:04is I'm just putting some oil up in the
1:58:07um let me get all the dust see it feels
1:58:10oily now when I touch it and that's good
1:58:11enough I can feel the oil on it but it's
1:58:13but there if you look you don't see the
1:58:15oil but it definitely feels oily you
1:58:16know how oil is you get oil in your
1:58:18fingers you can tell right you can't
1:58:20even wipe it off you wipe it off and
1:58:21your finger still feel oily that's all
1:58:23I'm doing
1:58:25here all
1:58:27right let's put it
1:58:30on and don't worry the moment this motor
1:58:33starts up within two seconds three tops
1:58:37the oil squirters right underneath this
1:58:39piston are going to be shooting just
1:58:40several strings of oil right at the
1:58:43Piston oh by the way I'm compressing the
1:58:45rings with my finger here and you can
1:58:47see that they have this little cut out
1:58:49out right here that's why I'm doing it
1:58:50right here on the sides of the
1:58:54piston and I'll start by putting let me
1:58:57get you let me get you up in here a
1:58:59little bit better hold
1:59:01on there we
1:59:03go and also let me double check this
1:59:06surface right here I know it's a brand
1:59:08new cylinder and everything but man I
1:59:10don't need no issues I don't need no
1:59:12water leak in I don't need nothing I
1:59:14don't want to get back inside of this
1:59:18motor okay the Rings are in their proper
1:59:20location I'm going to press them in
1:59:22their uh grooves you see how I got the
1:59:25back side of the cylinder the skirt part
1:59:27of the cylinder already pressing on that
1:59:29ring and then I'll try to there we
1:59:37go I think a ring snagged over here let
1:59:39me check yeah we got one Oil ring there
1:59:42it is I got it in the groove so just got
1:59:44to be gentle if a ring kind of jumps out
1:59:46of his seat you might have to fish it in
1:59:47with your fingernail
1:59:50if it starts
1:59:51biting pull it off and and check I feel
1:59:55a little bite right there let me see yep
1:59:58we got a ring out of it
2:00:04screw there we
2:00:10go there we
2:00:13go let me pull
2:00:16that timing chain up and out so it
2:00:19doesn't get
2:00:20[Music]
2:00:34binded there we
2:00:37go let me get that one bolt put it in
2:00:39there and we'll spin the motor by hand
2:00:41just make sure it's moving up and down
2:00:43freely okay I have that one bolt in
2:00:45there not real tight because till we get
2:00:47all the cylinder head bolts in you don't
2:00:49really want to tighten that one all the
2:00:50way
2:00:52down
2:00:53okay going to turn the motor by hand
2:00:57here all the way up and all the way
2:01:01down make sure everything's
2:01:04good ouch that hurt pinched my finger up
2:01:07in
2:01:09there lock put it top dead center here
2:01:12drop the timing chain back in there and
2:01:15we are good one more time verifying
2:01:17exhaust it's reverse motor so intake
2:01:19valves are up front looking
2:01:22good okay let's set her back in the
2:01:27frame okay here we
2:01:48go
2:01:57okay I got her setting in
2:01:59there start by fishing this one right
2:02:02here the bottom center one try to get
2:02:04that one in
2:02:07there this always helps when you have
2:02:09two people but I work by myself so
2:02:13that's how that
2:02:17goes
2:02:32okay got that one fished in
2:02:35there now I'll go ahead and get the
2:02:38front ones in place and then we'll be
2:02:40able to knock the swing arm pivot in
2:02:43okay all the motor mounts are in I have
2:02:45locked tight on the ones that go in the
2:02:46frame haven't tightened them yet I just
2:02:48got them finger tight in there so we can
2:02:50knock the swing our pivot bolt in you'll
2:02:52see this goo dripping out I what I do is
2:02:54I put um pj1 black magic chain lube I
2:02:58spray it all in there and fill that
2:02:59whole area up that stuff works really
2:03:01good on this stuff in my opinion it's
2:03:03better than grease because it kind of
2:03:04hangs around and I got it all
2:03:08over the that right there so let's go
2:03:10ahead and knock it
2:03:15in all right got to swivel the motor a
2:03:18little bit get it line up that's why I
2:03:19leave all the bolts
2:03:22loose let's
2:03:28[Music]
2:03:32see kind of pined in there a little bit
2:03:35there we go that's why I leave all the
2:03:37bows like that so I can just move it
2:03:40around there we
2:03:47go
2:04:09now I'm going to pump the back brake up
2:04:12so we don't forget to do that there we
2:04:14go told you I remind you towards the
2:04:17end all right put the
2:04:21washer and the nut on
2:04:28there okay let me go ahead and tighten
2:04:30up all these motor
2:04:47mounts
2:05:07okay to explain why I did some of the
2:05:08things I did you saw when I was tighten
2:05:10up the swing on pivot bolt that I lifted
2:05:12up on the rear wheel you'll see the
2:05:14whole motor shift and everything when
2:05:16you do that there's always a little bit
2:05:17of play with the swing on and the motor
2:05:19and everything if you don't shift it now
2:05:22it's going to shift after you start
2:05:23jumping big jumps and land it's going to
2:05:25shift on its own most likely you can
2:05:27take it off the stand and just uh let it
2:05:29sit on it Wheels tighten it up that way
2:05:31or you can just do like I did if you
2:05:32have an impact one hand an impact and
2:05:35one hand lift it up the rear wheel and
2:05:38high you know get get some good force on
2:05:39it you'll see the motor shift and
2:05:41everything and the swing arm shift and
2:05:42then tighten it up the two bolts down
2:05:45this one the 16 I mean the 14 mm here
2:05:47and here I did that with impact only I'm
2:05:50good with that um got it nice and tight
2:05:52if I accidentally stripped one out it's
2:05:54not the end of the world I can replace
2:05:55them U but these 12 mm right here I used
2:05:57the impact just to se them down and then
2:06:00I used a regular ratchet to uh to torque
2:06:03them down to bottom them out again my
2:06:05hands are calibrated I know how tight
2:06:06they need to be if you're unsure just go
2:06:09break out your manual that there's a
2:06:10link in the description for the manual
2:06:12break out your manual I used a little
2:06:13bit of lock tight on them too the reason
2:06:14I did them by hand is because you don't
2:06:16want to strip them out they go in the
2:06:18frame aluminum frame I'd rather do them
2:06:20by hand than use the impact I don't need
2:06:22to strip them out I don't need to strip
2:06:23that frame
2:06:24out okay I'll go ahead and get these
2:06:26water hoses on now might as
2:06:29well okay got the hoses on put that
2:06:32little cover on all
2:06:35right remember this we have to put that
2:06:39back in its
2:06:41seat hopefully you paid attention to
2:06:43which hole this came out of when you
2:06:45pulled it out so you know which hole to
2:06:47put it in when you put it in
2:06:49in okay I gave the sensor a wipe up I
2:06:52temporarily just set the the Stater
2:06:54cover on there modly so I can make sure
2:06:57the wires are not wrapped up around each
2:07:00other or
2:07:02whatever there we
2:07:05go and I'll put the bolts in for that I
2:07:08have lock tight on them as
2:07:13well dang it once a me once again I
2:07:16meant thread Locker holy cow I got to
2:07:18get this
2:07:26right
2:07:28he clutch cable on thread Locker on
2:07:39these this is about to be a wrap for
2:07:41this day got to go taking a street bike
2:07:44ride over to visit my dad tonight it is
2:07:47his birthday
2:07:49just going to jump on the ZX10R take a
2:07:52nice little cruise over there it's not
2:07:53too cold it's like 55 de out it's not
2:07:56too
2:07:58bad me get this gaset on there all
2:08:01right plus I haven't ridden that bike in
2:08:04like three or four months it needs to be
2:08:05put on the road all right new gasket of
2:08:11course we go I honestly I really only
2:08:15own it because if I don't own one I'll
2:08:17end up buying one when I work on
2:08:18somebody else's and I have to take a
2:08:19test drive it gets in my blood I'm like
2:08:22ah God I need another street bike so
2:08:25okay remember has these little this
2:08:27little tab that sticks up right there
2:08:28and there's another one right here
2:08:30that's where these little wire clip ones
2:08:35go I think this is one that goes up
2:08:44front maybe
2:08:46not trying to figure it out out
2:08:54here now that seems
2:09:00legit otherwise most my two wheel riding
2:09:03is on the
2:09:05dirt cuz I also enjoy owning a Mustang
2:09:09too so I get a lot of Play Ride you know
2:09:11play cruising around in that thing okay
2:09:14now you see it has the arrow here the
2:09:15ones with the arrow is where the little
2:09:17washer goes
2:09:20and we have two of them it looks like
2:09:22there's one there there's another arrow
2:09:23down here you probably can't see it on
2:09:24the camera maybe you
2:09:29can and then the other three just
2:09:32randomly go up
2:09:36here all right since D down nice
2:09:47tight
2:09:49put back around one more
2:09:54time just feel them all
2:10:07right there we
2:10:10go okay I have I that Hardware in there
2:10:13just need to tighten it
2:10:16up all righty
2:10:19all right what's next I guess I'll get
2:10:20the shift lever on
2:10:22there the Omaha likes to put a little
2:10:25dot right there and it matches the dot
2:10:27right there that's at least that's a
2:10:29stock setting at least you can change it
2:10:31if you want although you can change them
2:10:33they're usually pretty big
2:10:35jumps tighten that
2:10:38up front spocket
2:10:47time
2:10:55go we got one more tab that's in good
2:10:58shape here this other one's about to
2:10:59break off but we got one more good one
2:11:01here so it's good for one more
2:11:03usage I do not use locktite on these
2:11:06they have a locking tab um what happens
2:11:08is they end up getting rusty and stuck
2:11:11on there so to to um yeah just don't use
2:11:14locktite it makes it harder if they do
2:11:16get rusted it makes it nearly impossible
2:11:18get them
2:11:24off let me pull this off and move that a
2:11:28little bit so that tab is more right
2:11:38there let's try
2:11:47that
2:11:52move it one more
2:11:54over back the original
2:11:58Direction there we go and that's really
2:12:02why they give you two tabs it's not so
2:12:03you can use it twice is so that you find
2:12:05that perfect spot fold it over the
2:12:12nut all right that looks good snug it up
2:12:15a little better than
2:12:17that
2:12:19there we
2:12:32go grab something El here I'll grab that
2:12:35same old Flathead I used to get it
2:12:45off there you go I'm just trying to get
2:12:47it up h enough so I can grab it with
2:12:49pair of channel
2:12:51locks where are my channel locks
2:12:55anyway
2:13:10are h i notic this flashlight makes
2:13:13stuff like that go on like on the camera
2:13:16I think I'm going have to junk this
2:13:17Flash like that's a
2:13:21bu well that's a wrap for this video
2:13:24this is what I'll be riding out to my
2:13:25dad's house this evening go visit him
2:13:27for his birthday ZX10R 2012 um stick
2:13:31around for tomorrow's video where we put
2:13:33the cylinder head back on the YZ 250f
2:13:37and start her up for the first time see
2:13:39you guys tomorrow

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