Broke my bike...

[riffer]

It was all going so well.

I ripped the forks off this morning, replaced the oil, which was grey and kind of lumpy with the new purple coloured Spectro SAE20W.

All went perfect.

Then I took off the fairings to get the oil filter cover off to get at the oil filter.

Drained the oil out of the bike, undid the oil filter cover (its an aluminium finned jobbbie) and cleaned up the oily mess that landed all over my headers.

Got the new oil filter out. O-rings are the wrong size. Nevermind, I replaced them six months ago when I last did the filter.

Check with the Haynes manual. 15Nm of torque to do it up to, put everything back as per the manual, and just as the torque wrench goes 'click', so does the filter cover.

Hmm. Sounds a bit dodgy. Nevermind, fill er up with oil.

Start it up, and there's oil pissing out of the bolt hole in the front of the filter cover. It's got a bloody crack right down it.

Shit.

Needless to say, parts are only available ex-Japan (six weeks) and cost is around $150.


Not what I needed. So, looks like no bike for six weeks.


:argh:

[Deano]

You must be gutted. I often get paranoid about tightening up stuff that matters. I guess a torque wrench would be good but sounds like it didn't help in your case.

Dumb question but you weren't using Nm instead of Ft/LB's or vice versa ?

[Yokai]

Nooooo - man - that sucks.... I've been bikeless for 4 weeks now and I know how much a pain in the arse that is. You know of anyone that's got a wrecked one while you wait?

[riffer]

Dumb question but you weren't using Nm instead of Ft/LB's or vice versa ?

Yeah, I thought of that at first, but I think it's just wear and tear to be honest.

The only thing that's cheering me up at the moment is the 2NK-spec CDI making its way over from the US as we speak.

At least when it goes back on the road it will be making some serious power at the back wheel.

Pity I can't deregister it for six weeks.
:thud:

[riffer]

Nooooo - man - that sucks.... I've been bikeless for 4 weeks now and I know how much a pain in the arse that is. You know of anyone that's got a wrecked one while you wait?

Yes. I will be hitting them up for a loan as soon as I can contact them. Still going to have to bite the bullet and pay for another oil filter cover unless I can find someone wrecking either an FZR750, FZ750, or FZR1000.

[Ms Piggy]

Stink mate. I have no mechanical knowledge, so all I can offer are sympathies.

[NC]

:weep: Poor wee bugger

[Bonez]

Not what I needed. So, looks like no bike for six weeks.


:argh:
Can you not get the thing ali welded?

[ajturbo]

Can you not get the thing ali welded?

my mate welded a piston for me..raced with it for over a year!!!

[marty]

bugger.....................

[FROSTY]

Yes. I will be hitting them up for a loan as soon as I can contact them. Still going to have to bite the bullet and pay for another oil filter cover unless I can find someone wrecking either an FZR750, FZ750, or FZR1000.
Mate there is one winging its way to you as we speak.
from a fz750

[Motu]

Maybe the filter housing wasn't quite lined up when you torqued the bolt? I don't trust torque wrenches,after 35 yrs in the trade I've got my own built in job.Once I was doing a V4 Johnson and as I didn't really know what I was doing ,I torqued every bolt to spec - and yeah,stripped some head bolts,next time I did it my way.

Cleaning my floors at work today,so fitted a new tyre to the XT between scrubs and blasts and queeges - so thought I might fit my race TT rear shock.It was a tight fit and had to relieve the frame and shock eye,hell of a lot of mucking around,then adapting the lower eye to the link,had to make spacers and stuff.Got it all set and went to put in the lower link pin - and find it's a bigger size! Bugger,all that work for nothing,and I got a leaky tank again too.Sometimes it just pays to leave them alone eh?

[crashe]

thats a real buggar aye.... doing all that work and its then snaps.... :weep:

Aint Frosty a neat guy.... sending the part that you needed down to you....
Hope you are back on the roads real soon. :cool2: :niceone:

[James Deuce]

Thank GOD for Frosty!

I couldn't have coped if both of us had been whining!!

[Ghost Lemur]

...Sometimes it just pays to leave them alone eh?

Blasphemy. :msn-wink:

[riffer]

Thank GOD for Frosty!

I couldn't have coped if both of us had been whining!!

Tell me about it Jim!

You were just about to be called up and whined at.

Frosty. I owe you ... again.

A very cold ale is yours any time you are down here.

Which reminds me. As you wife to be's family is in Upper Hutt, when will we be seeing the two of you down here?

[FROSTY]

Celtic-text me ya addy --and call Lynda--021443399

[Blakamin]

YAY...a solution... when I started this thread, I thought I might have to lend you my Duc for a week until work dies down.... :bash: (fat chance really)
whew.... back on the road in no time!!!!!
then you can ride over here oneday!!!!

[avgas]

alls well ends well.
good on ya frosty

[Bonez]

Cleaning my floors at work today,so fitted a new tyre to the XT between scrubs and blasts and queeges Shit, that reminds me. Must fit the Shenko to the 550 before I use it next.

[FROSTY]

Um er -celtic--um I let ya down dude.
The front of the motor is muntered -I knew there was a reason I tossed it under me house--fuggit.
so we go to plan B
Given ya have a crack in the filter HOUSING.
1) remove filter housing and wash well in petrol
2) take filter housing inside and grease up to MRS celtic.
3) wash the filter housing in HOT soapy water
4) using a triangular file or a 100mm angle grinder with a cutting blade grind a groove down the crack
5) using Knead it High temp fill the groove

[riffer]

Um er -celtic--um I let ya down dude.
The front of the motor is muntered -I knew there was a reason I tossed it under me house--fuggit.
so we go to plan B
Given ya have a crack in the filter HOUSING.
1) remove filter housing and wash well in petrol
2) take filter housing inside and grease up to MRS celtic.
3) wash the filter housing in HOT soapy water
4) using a triangular file or a 100mm angle grinder with a cutting blade grind a groove down the crack
5) using Knead it High temp fill the groove

Well I guess its worth a go.

One concern:

How strong is Knead It?

If I have cracked the bit around where the bolt is, will it hold when I do it up again?

I'll have to make a trip to the Warehouse and score a cheap angle grinder in the morning...

[FROSTY]

dont do that mate.Knead it is pretty strong as long as ya follow instructions.
the point is to get a surface for the knead it to adhere to.it wont work if its just stuck on the face of the ally.
There was actually some stuff for ally welding kinda like solder. It had a very low melting point (for metal) and will run like solder does into the groove.

[riffer]

Is this the stuff Frosty?

http://www.mitre10.co.nz/products/item.asp?lSKU=370325&loggedin=False

[spudchucka]

You'll find there are heaps of different grades of the same product for different purposes so spend some time and make sure you get the right one. The only one I've used is the marine grade for repairing windsurfers, its really easy to use and I've never had it fail.

[Stevo]

I own an FZR and can sympathise with you mate. Almost everything has to come ex Japan. They don't seem to have heard of airmail though?? I can get Honda parts from the States for my Hondas in 5 working days yet effing ex Japan parts seem to be 3 weeks!!!!!!! Japan is even Closer!!! Had the FZR out of action for 6 1/2 long weeks but thankfully it was June/July and not mid summer.
Soon I shall have the CBR going when my ex Japan effing headlight loom arrives. Goddamn! I shoulda got one off eBay. I'd have it by now :whistle:

[riffer]

I own an FZR and can sympathise with you mate. Almost everything has to come ex Japan. They don't seem to have heard of airmail though?? I can get Honda parts from the States for my Hondas in 5 working days yet effing ex Japan parts seem to be 3 weeks!!!!!!! Japan is even Closer!!! Had the FZR out of action for 6 1/2 long weeks but thankfully it was June/July and not mid summer.
Soon I shall have the CBR going when my ex Japan effing headlight loom arrives. Goddamn! I shoulda got one off eBay. I'd have it by now :whistle:
Actually guys maybe this is more like the stuff. (http://www.selleys.com.au/products/live/260/158.asp) I guess some more metal-reinforced epoxy on this bike is not going to hurt - after all, the headstock is full of the stuff!

Cheers for the heads-up Frosty.

[FROSTY]

Actually I was thinking//remembering. A couple of years ago there was a product for repairing ally.
It was available in hardware shops and looked like stick solder.
Ya heated it up and it seemed to stick well to ally.
Might be worth a phone call or two.
If ya go with the epoxy option--follow the instructions -to the letter
If you are going to mix it with bare hands --wash them thoughroughly before and after.

[riffer]

Actually I was thinking//remembering. A couple of years ago there was a product for repairing ally.
It was available in hardware shops and looked like stick solder.
Ya heated it up and it seemed to stick well to ally.
Might be worth a phone call or two.
If ya go with the epoxy option--follow the instructions -to the letter
If you are going to mix it with bare hands --wash them thoughroughly before and after.


Okay, I went with the epoxy option.

I took the oil filter cover off this morning and gave it a good wash in isopropyl alcohol. Looking at the inside of the filter cover there is a crack that runs in a circle about two inches in diameter around half the cover. There is also a crack on the outside around where the bolt that holds it on screws on.

So, I got out the dremel tools and filed a groove where the crack was on both the outside and inside of the cover. Then I filed away around the groove to make a nice shiny rough surface.

Then cleaned it all up with isohol again and got out the quicksteel. Kneaded it until the gray and black was completely mixed together (it gets warm, doesn't it?) then pushed it into the groove, then gradually built it up until it covered the crack on both sides. I made sure it was nice and thick and built it up to the flange height. I checked that it wouldn't foul with the oil filter (good idea - one that usually comes after its set).

Then I built up the outside and scraped it back so it wouldn't foul with the bolt.

Then I left it for an hour to dry.

Once it was dry I sanded it all back so it was like a nice smooth flange on the inside and on the outside I sanded it back so that it was like it was the original shape.

Then I cleaned all the sanded stuff out with the isohol again, dried it off then assembled it all again, making ABSOLUTELY sure that it was as tight as I felt it should be (not with the Torque wrench this time), and filled the bike with oil.

Once it was filled with oil, I started it up and let it idle for a minute or so to let the oil filter fill with oil again. So far so good, no leaks. Then after a minute or so, rev it up to 3-4000 rpms, check for oil leaks. No leaks.

Excellent stuff. So I've left the bike for the day.

Great call Frosty. The stuff seems to be working so far. I'm not too sure about its long-term efficacy. Have you used it for any length of time?

Only real hassle is the stink the stuff leaves on your hands. My hands still smell even though I've washed and washed and washed.

Small price to pay, I guess.

[enigma51]

Okay, I went with the epoxy option.

I took the oil filter cover off this morning and gave it a good wash in isopropyl alcohol. Looking at the inside of the filter cover there is a crack that runs in a circle about two inches in diameter around half the cover. There is also a crack on the outside around where the bolt that holds it on screws on.

So, I got out the dremel tools and filed a groove where the crack was on both the outside and inside of the cover. Then I filed away around the groove to make a nice shiny rough surface.

Then cleaned it all up with isohol again and got out the quicksteel. Kneaded it until the gray and black was completely mixed together (it gets warm, doesn't it?) then pushed it into the groove, then gradually built it up until it covered the crack on both sides. I made sure it was nice and thick and built it up to the flange height. I checked that it wouldn't foul with the oil filter (good idea - one that usually comes after its set).

Then I built up the outside and scraped it back so it wouldn't foul with the bolt.

Then I left it for an hour to dry.

Once it was dry I sanded it all back so it was like a nice smooth flange on the inside and on the outside I sanded it back so that it was like it was the original shape.

Then I cleaned all the sanded stuff out with the isohol again, dried it off then assembled it all again, making ABSOLUTELY sure that it was as tight as I felt it should be (not with the Torque wrench this time), and filled the bike with oil.

Once it was filled with oil, I started it up and let it idle for a minute or so to let the oil filter fill with oil again. So far so good, no leaks. Then after a minute or so, rev it up to 3-4000 rpms, check for oil leaks. No leaks.

Excellent stuff. So I've left the bike for the day.

Great call Frosty. The stuff seems to be working so far. I'm not too sure about its long-term efficacy. Have you used it for any length of time?

Only real hassle is the stink the stuff leaves on your hands. My hands still smell even though I've washed and washed and washed.

Small price to pay, I guess.


Just check it after every ride. It should be fine. Ship mechanics use the same stuff to fix engine cracks at sea.

[mangell6]

CelticNo6 - Some luck has to come your way . . . . . . .

[James Deuce]

CelticNo6 - Some luck has to come your way . . . . . . .


He'd need to buy a Honda for that to happen. Fekkin' Yamahas.

[Blakamin]

Jeez... the heart was pounding about lending him the Duc again....

will be over your way monday morning CN6, you home or working???

[pete376403]

Simon, if all else fails, Scotts FZR isn't going to be running for a while (if ever) so I could probably get the cover from his motor. (even if the gear box parts arrive, still need to get the gasket set from Oz, find the time to pul it all apart, etc, etc)

[riffer]

Simon, if all else fails, Scotts FZR isn't going to be running for a while (if ever) so I could probably get the cover from his motor. (even if the gear box parts arrive, still need to get the gasket set from Oz, find the time to pul it all apart, etc, etc)
Thanks Pete. If my fix job doesn't work I may be in need of a cover.

Actually, if it fails it'll probably be on the takas and will spill oil on my back tyre causing me to arse off into the traffic so I'll probably be looking for another bike ;)

It hasn't leaked yet so fingers crossed...

Mike - I'm at home Monday. Back to work on Wednesday... Look me up.

[Blakamin]

Thanks Pete. If my fix job doesn't work I may be in need of a cover.

Actually, if it fails it'll probably be on the takas and will spill oil on my back tyre causing me to arse off into the traffic so I'll probably be looking for another bike ;)

It hasn't leaked yet so fingers crossed...

Mike - I'm at home Monday. Back to work on Wednesday... Look me up.
Will be around!!!

[inlinefour]

It was all going so well.

I ripped the forks off this morning, replaced the oil, which was grey and kind of lumpy with the new purple coloured Spectro SAE20W.

All went perfect.

Then I took off the fairings to get the oil filter cover off to get at the oil filter.

Drained the oil out of the bike, undid the oil filter cover (its an aluminium finned jobbbie) and cleaned up the oily mess that landed all over my headers.

Got the new oil filter out. O-rings are the wrong size. Nevermind, I replaced them six months ago when I last did the filter.

Check with the Haynes manual. 15Nm of torque to do it up to, put everything back as per the manual, and just as the torque wrench goes 'click', so does the filter cover.

Hmm. Sounds a bit dodgy. Nevermind, fill er up with oil.

Start it up, and there's oil pissing out of the bolt hole in the front of the filter cover. It's got a bloody crack right down it.

Shit.

Needless to say, parts are only available ex-Japan (six weeks) and cost is around $150.


Not what I needed. So, looks like no bike for six weeks.


:argh:

Hope it is all sorted out now :beer:

[riffer]

Hope it is all sorted out now :beer:

Sorted ages ago buddy. Thanks to the wonders of knead-it quick steel!!!