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1975 400/4 project
Rozabikes Tim:
Re U-tube on this. There is a pretty good strip / rebuild thread out there but remember when I was taking clutch off, I referenced that bit in the video as I was wondering how he locked the engine. Haynes made no reference either. He said something like his mate had a special tool (that we all know you need). However the video then flicked straight into clutch having been removed, so you did not see any locking method used.
Sprocket:
See I was worried about that too, but in my case the large nut wasn't in any way tight. After I unbent the retaining washer thing, I could unscrew it without needing to even use the clutch socket thing I bought! I feel like it's one of those that you need to 'shock' loose if needs be, with an impact driver.
Rozabikes Tim:
--- Quote from: Sprocket on February 12, 2019, 10:30:55 AM ---See I was worried about that too, but in my case the large nut wasn't in any way tight. After I unbent the retaining washer thing, I could unscrew it without needing to even use the clutch socket thing I bought! I feel like it's one of those that you need to 'shock' loose if needs be, with an impact driver.
--- End quote ---
Just locked the gearbox via final drive as suggested on this very forum. It was just if you are gong to do such a video and take all that time, why not cover difficult parts, assuming the idea was to help others. :P
I had mislaid my tool for the job but far too impatient, so fashioned a 2 prong version with some flat steel. Did the job with adjustable spanner for leverage.
Bryanj:
Kawasaki had a workshop tool that was big molegrips with bent long legs that clamped into the inner splines, was quiet cheap when i was doing them so bought one
Sprocket:
So after some flu and other 'life events' I finally got round to taking the most final step and splitting the cases. Stubborn front mount bolt still there, I worked around it with a spanner and have left a bolt in for the engineers to fix. Also there's what's left of a sump bolt still in the bottom half, I may have a go or I may let them deal with it.
As expected the camchain adjuster locking bolt thread has completely gone though, which is disappointing. I was so careful not to touch it until I'd split the cases! I wound it in, looked at the end for any sign of mushrooming, there was none. Extracted what I thought was a little loose gunge on the end, then gradually back and forthed it. Bolt looked ok, but the thread inside has completely disappeared.
I did note the bolt wasn't straight too, which I assumed was going to be a problem. But on inspection inside, there is a drilling hole in the casting that isn't straight, so I'm not sure that's actually a problem. Ah well, will let the engineers sort it out.
Overall was pleasantly surprised there was less loose metal in there than I was expecting, but I did find the source of the other mysterious swarf in the sump. Top gear. Seems like it could be a common issue too, judging by how many gear sets are for sale without this one, or with it damaged ;D
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