Rebuilding the GP100

[F5 Dave]

Sounds heavy.

[Skunk]

About the same as a coin, goo and knead-it.

[Slingshot]

A dished plug that is hammered into the hole. They are used in (older) cast iron engine blocks on cars to fill the casting holes needed to form the water jacket. They are availble from Repco, Tonys Auto Centre (Tory St) and the like.

I know what you mean, but I suspect that hammering one of those into the thin alloy casing could create a few issues

[Skunk]

Nope, do it all the time. Measure the kickstart hole carefully and buy the plug marked with that size. Put a socket in it and hit it. Done.

[Trudes]

"How to measure a Butt Plug" by Skunk.

[Kendog]

That was pathetic. Try again.

I got nothing........

"How to measure a Butt Plug" by Skunk.

But that is gold

[koba]

My old KLR had a piece of plastic made to the shape and carefully placed behind the seal that normally sits in there. I bet it was worth a good half gram.

I took part of the ratchet off the RG when I broke the return spring but it is all back in there now as I got sick of pushing very quickly.

[Slingshot]

Next question:

How important is the main bearing retaining plate? I can't find one in my box of bits but the Haynes manual is telling me to stick one in.

Can I do without it?

This is what I'm talking about.

[F5 Dave]

Main bearing? You mean clutch shaft bearing. I had a crank main bearing move when the plate undid & it scraped on something. I'd find one & apply loctite to the screws.

[TZ350]

Next question:

How important is the main bearing retaining plate? I can't find one in my box of bits but the Haynes manual is telling me to stick one in.

Can I do without it?

This is what I'm talking about.

You defiantly need that plate, PM me if you cant find yours and Ill send you a spare. Also there should be a washer on the small end of the output shaft where the index finger of your left hand is in the picture.
.

[Slingshot]

Main bearing? You mean clutch shaft bearing. I had a crank main bearing move when the plate undid & it scraped on something. I'd find one & apply loctite to the screws.

Actually...I meant mainshaft bearing (that's how the Haynes manual describes it). Clutch shaft is even more descriptive

You defiantly need that plate, PM me if you cant find yours and Ill send you a spare. Also there should be a washer on the small end of the output shaft where the index finger of your left hand is in the picture.
.

I haven't got a hope in hell of finding it...PM will be sent shortly

PS...that's not my left hand in the picture, it's the finger of Mr Haynes...and I have put a washer on that shaft, hopefully it's the right washer...it seems to fit reasonably well.

[holloshaw]

weres the best place to get a Haynes GP100 manual? an ebook would be perfect

[Slingshot]

weres the best place to get a Haynes GP100 manual? an ebook would be perfect

I got mine off Trademe. There are lots on eBay.co.uk.

[Slingshot]

I'm in business again!

A parcel turned up this morning with a replacement plate, a thrust washer and a selector fork!

TZ350...You're a legend!

[Slingshot]

I've just joined the two crank case halves. They seemed to go together nicely, but it's pretty much impossible to turn either the output shaft or the clutch shaft by hand...I expected that these would turn freely.

Have I fucked up?