Going to have to split the cases

edjo · Post by **edjo** » Fri Aug 31, 2007 3:32 pm

I took off the cylinder and head today to get it ready for the new parts. Once I got the cylinder off I noticed that the piston was in pieces. I am going to have to split the cases to clean up the debris, everything is turning real smooth though so I am no too worried. So whats the quickest way to get the whole engine assembly out?? Thanks guys, Ed

Pygmaelion · Post by **Pygmaelion** » Fri Aug 31, 2007 6:13 pm

Here's what I recall from taking off a '94 dio engine.

1) remove the bolt that attaches the rear shock to the engine casing

2) take off the spark plug coil from the plug (you can leave the plug in for now.

3) trace the wires from the starter/bystarter.alternator up toward the connectors on the harness. Detach each of them. I list them together, because I think they pretty much trace to the same locale.

The only thing now holding the engine to the bike is the big * main bolt on the kickstand. It took putting a box end wrench on one side, and getting a socket, ratchet handle, and big cheater bar on the other side. Plenty of steady pressure to the counter-clockwise direction will get the nut off (don't try turning the bolt, go for the nut). Pull that bolt out, and the engine will drop off.

Once the engine is separate, you can take it apart in as painstaking a fashion as you wish. put your parts in the dishwasher. It's nice and hot, and gets things good and clean. Don't run it with your favorite coffee mug.

I urge you to take your time getting the flywheel, key, and crank out... Don't attack it with impatience and brute force.

Dac · Post by **Dac** » Sat Sep 01, 2007 7:56 pm

if you have the carb off, gas tank empty, and oil empty you can just tip the hole thing over. if you have a air compressor blow it out some, pulling the kick starter helps also

edjo · Post by **edjo** » Sun Sep 02, 2007 12:07 am

Yeah, I was looking at it again today and trying to figure out how I could clean it out with out splitting the cases. I may try your idea, or just remove the motor assembly and turn it upside down and blow it out with some oil spray and the compressor. I got the lights mounted today, the battery mounted and secured. It may get a sticker job instead of paint, I want to keepo the "rat" look going.

Dac · Post by **Dac** » Sun Sep 02, 2007 1:15 am

yeah that might be better for you. when i fried my piston some of the bottom busted and fell in.VtCycles said to make sure NONE of it was still in the case.
before i put all my stuff on it i had it down to almost bare frame so i just fliped, sprayed mass amounts of starter fluid ( not the best stuff but it worked ) in the reed valve hole and crank it self. then took my air compressor and blow it all out. to my surprise i got 4-5 little pieces of metal out of there