Motorcycle Engine Rebuild the Tear Down

www.rrrtoolsolu...
We are preparing to do a Motorcycle Engine Rebuild. This is the engine tear down. We speed up the entire process, so you can see the complete engine tear down.
We use our DIY Motorcycle Engine Stand to hold our motorcycle engine during the motorcycle engine rebuilding process.
Hi, Gordon the Tool Guy here. Today we're preparing to do a Motorcycle Engine Rebuild and we're starting off with an Impact Driver by Vessel to remove the Engine Case screws. We'll use the Impact driver to loosen all of the crankcase screws.
This is the left side cover and holds the Stator Coil. The Rotor and Stator generate AC - alternating current (3 Yellow Wires) for our charging and operating current. The Alternating Current runs through the Rectifier which converts it to DC - Direct Current.
Most motorcycles have a separate lighting coil, but on this particular off-road model, lights and the lighting coil are not installed. The Green Wire and small screw are the Neutral Sensor Wire.
Here is another look at the Stator Coil and Rotor.
A Compressor and Air Impact make quick work of removing the Rotor Bolt We need to start the threads of the puller by hand to be sure there is no cross-threading that would permanently damage both the Rotor and the Puller
Again, the Compressor and Air Impact wrench make quick work of removing the Rotor.
With the Rotor removed, we can see that the back side is also a Starter Clutch. The small electric, 12 Volt starter motor turns the small gear, the small gear then turns the larger Starter Gear. When the Starter Gear is driving the Rotor, the Rollers are clamped onto the Crankshaft Gear and Hub.
As soon as the Engine starts, the rotational speed and load releases the Rollers and centrifugal force keeps them pulled out and away from the crankshaft gear.
We remove the Woodruff Key and gears, the starter pinion shaft. Now we're ready to turn this assembly over and disassemble the other side.
Working now on the Right Side, we'll remove the Crankcase cover and expose the Clutch and Oil Pump Using the same Impact screwdriver, we loosen and remove the crankcase screws. We remove the Oil Filter Cover and Filter We remove the Electric Starter
Light tapping around the cover with a plastic mallet and the cover is easily removed
This is the Clutch Assembly - we're looking at the Clutch Pressure Plate, Basket, Friction Disc, and Clutch Plates. We'll start by removing the Springs that are held in-place by these 6mm screws/bolts. I like to remove the tension on the screws/bolts evenly
The Clutch Pressure Plate comes off first, then the friction plates and disc. We'll cover these parts and how they work in a separate video. The locking tabs are opened so that we can remove the large Basket Nut.
Using the Clutch Holding Tool, we can use our Air Impact Wrench to remove our Basket Nut. We can then remove the Inner Clutch Hub and the Clutch Basket itself. The locking tabs are opened and the correct socket chosen
We pull the sparkplug from the cylinder head so that we can rotate the crankshaft and gain access to the Oil Pump screws Using the Air Impact Wrench, the crankshaft and engine balancer shaft nuts are removed The Woodruff Key is removed from the Crankshaft
We pull the Shifter Shaft and the attached Detent, the Centering Spring Guide, and Ratchet Assembly Removing the Oil Pump screws is easier now and we work through the holes in the drive gear We lift the Oil Pump away and remove the displacement rotor
The crankshaft gear is removed.
We position our engine in the Engine Stand so that access to the cylinder head and cylinders easily. This repositioning demonstrates why we like this economical DIY Engine Stand a lot. We remove the Camshaft Sprocket nut then sprocket
The cam chain is pulled down through the cylinder The cam chain tensioner is removed we reposition the engine in our stand to access the head bolts
The head bolts are loosened evenly and carefully so as not to warp the head. Bolts are removed along with their special Copper washers - Copper being a softer metal that provides sealing.
Two 8mm bolts along the side removed The head just lifts off and exposes the head gasket, locating dowels, and the special sealing dowels that carry oil to the top end.
The small 6mm bolts are loosened and removed from the base of the cylinder With the small bolts removed, we can lift the cylinder off the case and piston The rubber cam chain guides pull up too
A quick look at the cylinder bore shows wear and vertical scratches which usually means dirty/contaminated oil and improper lubrication
We reposition the engine in our engine stand so we can access the Center crankcase screws. This is the next step before splitting the case. We remove the cam chain guide

[@jthepickle7]

It's been 4 years. Are we going to put it back together?

[@Daniel-oj2xe]

We are still waiting bro to rebuild that engine !

[@t-t8753]

Hahahaha yeah

[@fahvm4362]

Just reverse the video...Tenet !

[@willieboy8798]

i could have used this 50 years ago!!! i used trial and error instead... good video

[@davidkrempaszky2325]

Wow you made that look so easy, seamless and awesome video!! I can't wait to give this a go one day!!

[@RRRToolSolutions1]

David, thanks for the comment! We enjoy working on these.

[@antongaleton4444]

hahaha I already tried it, it turned out very good))

[@ke_ag]

HEY GORDON THE TOOL GUY HERE

[@edbroaotearoa1198]

Excellent video thanks

[@karremollo3495]

Nice video sir....can you please do a disassembly on a twin V-TYPE engine sir on yamaha? 😃😄😆

[@jeandebeer5470]

thank you sir

[@DRnutterbutters]

Awesome video. I’m in the middle of rebuilding my first one. I’m stressed about it. Seems so complicated. I need to see the rebuild. Did you have a video for that

[@TeamXtrm]

I too am doing my first tear down, got to check the transmission! Dreading it, mostly the rebuild.

[@car5car5]

Takе lots of pictures and put all parts in plastic bags, use marker so you don't install crankshaft in place of transmission shaft. :)

[@tron.44]

@@car5car5 that's actually a brilliant idea!

[@sabithossain2040]

You are doing a great job sir.Best of luck

[@RRRToolSolutions1]

Thanks for you feedback and taking the time to comment. RTS

[@TonySMotorcyclePassion]

Brilliant.Thank you. Best every

[@RRRToolSolutions1]

Thanks for commenting!

[@crosstechheavy6453]

The old path...God bless.....thanks

[@esatd34]

Nice speed, nice voice, nice explanation

[@RRRToolSolutions1]

Thanks for the kind comments and taking the time to provide feedback! Gordon/RTS

[@jackb9146]

Great demonstration. Thanks

[@teranhughes77]

How does one keep track of all the screws and bits to make sure everything goes back together absolutely correct?

[@allseeingguy5485]

Take lots of pictures, or organize them in labeled plastic baggies. This is certainly no small feat.

[@andrew_trucker]

take pics and put tags and notes on everythign as well as buy a book on the bike your working on mostly by photos and notes although ! use gerber glass jars and mark those for each part use a container . If your a lesbian use a Cuntainer. make diagrams. see if you can attack wires with tags to parts as well. tags like baggage tags . marks also left or right inside outside. and if you have to upside down or 69 lol.

[@antongaleton4444]

Learned to disassemble cheers))

[@motorart4670]

Nice video. In an engine rebuild, which parts are typically replaced to bring an engine up to spec again. I know it's usually the Piston and rings...what other parts need renewing?

[@jamerson808]

incredible video man great job

[@RRRToolSolutions1]

Thanks for commenting!

[@baisiji_julia_w]

bravo

[@dextermuring6425]

Excellent

[@abhinayrevs6283]

Awesome video guys ... keep up

[@jannixtvAdventures]

it helps me alot... thanks for uploading...

[@RRRToolSolutions1]

You are very welcome Jan.

[@jannixtvAdventures]

RRR Tool Solutions 864-710-7964 do you have tools dealer in Philippines?

[@RRRToolSolutions1]

Jan, we don't. I can ship there if you want to purchase, just let us know through the website "contact us" page what you need and I'll quote you a shipped/delivered price. Thanks, Gordon/RTS

[@collectiquepitakotte3837]

Can you put a video of tearing down of Yamaha SR250? Please

[@JaimeNavidad]

Well done! Thanks

[@birdy9922]

Great vid! I am preparing to tear down and completely rebuild the engine on a 1979 Suzuki GS 550 L. Air-cooled 549 cc inline-4, DOHC, 8 valves. This will be my summer project to convert the bike into a scrambler. The bike has both an electric ignition but also a kick-start. Anything special I need to be aware of before I start the disassembly? Or better yet, do you have a video showing the disassembling of an engine with kick-start? Better, better yet...can you just come help me do it? :)

[@luislazcano5563]

Excelente video .... muy educativo...

[@RRRToolSolutions1]

Gracias trabajamos duro para hacer buenos videos Thanks we work hard at making good videos. No se olvide de compartir con sus medios de comunicación social. Don't forget to share with your social media.

[@enioruffato]

Muito bom, parabéns pelo video! Obrigado

[@morbusj2312]

Do you have a link to the clutch holder tool you used in this video? Or maybe a tool manufacturer/model number?

[@omarreyes2401]

What engine is he dissecting?

[@johannmendoza5681]

Same question

[@mrutube4701]

PLEASE Tell me Bmp Pike 200cc piston ring gap definition Please 🙏

[@MrCommeci]

gut gemachtes Video

[@bobbymckinney1264]

I have a suzuki gz250 is there suppose to be oil in the stator mine has oil in there I didn't know for sure if the oil might had burned my stator?

[@pobletechannel8685]

Nice cool new friend here .hug

[@alimsuzuki8125]

amazing

[@billadmond9450]

This engine looks quite similar to the one fitted on the Suzuki TU250 series so do Japanese manufacturers copy each other or what?

[@radulacatusu4154]

How do you remember to assembly everything back together?

[@valentindalino3255]

Nice one,and very informative

[@coollkubi]

this a lot work

[@azlanrahem2999]

Im speechless

[@joshuarigby5799]

May you do a piaggio fly 125 non online and re assy

[@exoduzsabatth8772]

is that its?we're the continue?

[@BiBiiBuTV]

Do you have a video of assembling this engine? Thanks great video.

[@RRRToolSolutions1]

Hi Lezer, I don't. I had every intention of filming the assembly, but my brother had a wreck and then took a full-time job. I lost my camera man and editor, so I just could not film it. Thanks for commenting! Gordon

[@mannyagrinya1529]

Sorry about your brother. Hope he recovered/is recovering ok. Great video.

[@drama8019]

What kind of engine is this I am a newbie

[@ivanrico9200]

Where did you get the right case engine

[@robertbrandywine]

So the rotor and stator sit in oil?

[@RRRToolSolutions1]

Yes, these components are wet and operate in an oil sump environment as almost all Japanese motorcycle and ATV engines do. Thanks for commenting - Gordon/RTS

[@samqueen8337]

Yes. The oil cools down the stator.

[@eduuriosguerrero3781]

It is an XT200cc from Yamaha!!!!

[@pervaizali6533]

which engine is it?

[@karremollo3495]

I have a dragstar 400 2004 model..so bad I need to do something to recondition its engine...i dont how to it..:(

[@karremollo3495]

Do*

[@athafawwazrudiyanto5966]

similar to my yamaha, from what motorcycle is this engine?

[@athafawwazrudiyanto5966]

wow, my feeling just very good. i though it's yamaha in the begining of the video until you flip the engine and i see this 1:53 . but i still don't know the bike.

[@RRRToolSolutions1]

This is a 2000 year TTR 225. It's the same engine they used in the Serow. Great little engine, reliable, and dependable. Thanks for commenting - Gordon/RTS

[@leonrero4227]

what do you call that matter falling,pause to 4,35

[@RRRToolSolutions1]

Good eye! That was the clutch push rod. That rod slides inside the shaft to push the assembled clutch basket open (allowing bike to stop or shift). There is also a small ball that goes at the end to act as a bearing. Thanks for commenting. Gordon/RTS

[@abhiguha4314]

I could never put that back to original form lol

[@juliazatorska4296]

What size bolt pulls out magneto?

[@ivortheengine14]

Julia Zatorska The same size bolt and thread that holds the rear wheel to the swing arm

[@ins3rti0n]

4:35 whoops, lost something there lol

[@Francois_Dupont]

dont you have a proper impact screwdriver?

[@miguevilla1026]

**You started the engine disarmament wrong. the process is wrong. It always starts by the head of strength was more by making the video** 😵😵😵😵

[@preciousreading1934]

A little fast.