RG - Extensive clean

**Arronduke** · 30th May 2014, 22:33

And forgot to add.. all the rear wheel spacers are made. Everything looks great.
Happy with the final result.

pictures you ask, we all like pictures. Funny thing is the less in a picture the more we like it!

**Arronduke** · 7th June 2014, 23:26

The bike is now nothing but a pile of bits.
Boxes of steel and electric wiry stuff.

Motor is out and in it new fancy engine thing.

Swing arm is at the welders getting a torque arm mount welded on.

**Arronduke** · 19th June 2014, 03:42

Torque arm is back and welded on to the swingarm.

Looks cool.

Time to pull this motor apart and give it some Loven...

Think I have found the oil leak....!

Wonder who is to blame for that f#ck up... that was a new seal!

cranks are out.

Got to love this engine, small powerful... with two cranks..

**unstuck** · 19th June 2014, 06:15

Thats a niffty looking engine cradle there fella, homebuilt?

**Arronduke** · 20th June 2014, 02:44

Here is what I used to separate the crank cases, 8mm nut and bolt.
You will need to file 0.4mm off each side of the nuts to fit in to the recess and the screw the bolt in evenly at both ends and bingo they separate.

Got the cranks out, now I need to find someone to rebuild them...anyone know who can do this?

This here is a great tool, used heaps to hold things when it says in the manual that you need an expensive special tool. Add a impact gun and bingo nothing can beat you.

That there people is the gear box. Designed to be removed quickly without needing to separate the crankcases. Other words known as a cassette gearbox.
Pretty cool, shame they are a little fragile and tend to go bang. Hence the new stronger gears I have to rebuild this sucker.

I still think this is way cool.

Now this is where the fun starts.... I noticed very fine ali in the residue oil .....WTF. Have a look in the last picture and you will see the problem.

Lets have a closer look....

Dam bearing has spun in the blind hole in the back off the crankcase.. going to need this fixed.. help anyone with ideas?

with bearing sitting in the offending hole... my guess is it needed to be bushed... cant see it being welded and machine...

**Drew** · 20th June 2014, 06:25

The clutch holder is cool. I usually sacrifice a clutch steel and weld a handle to it.

For the case where the bearing has been spinning, I have no idea. Find the most trick looking engineering shop you can, and ask them.

**Hobbyhorse** · 20th June 2014, 07:39

Don't know where in Auckland you live but I use Rex Cotterell at 365 Rosebank Road Avondale for tricky stuff in the engineering line.

**HenryDorsetCase** · 20th June 2014, 09:57

I love this thread.

Liking that bike: not so much the paying for the motor rebuild...

I am interested to see how it gets repaired.

**NAR RG500** · 20th June 2014, 10:05

I'll sell you a new case for a million dollars.

You could get the pocket machined out and a steel sleeve fitted to bring the size down to original O/D. Will be fairly painless for a good engineer.

Also check your shifter drum bearing for sloppiness as you will probably have to get something done about that at the same time, although if it's not real bad some retaining compound normally works fine.

Cheers

**Ocean1** · 20th June 2014, 19:07

Originally Posted by Arronduke

Dam bearing has spun in the blind hole in the back off the crankcase.. going to need this fixed.. help anyone with ideas?

Any good machine shop will overbore it and press in a sleeve. Can't help with good shops in Orks though.

Whoever does it will need the rest of the case assembly and shaft, to pick up the precise original location of the shaft centre and counterbore depth.

**Arronduke** · 22nd June 2014, 18:26

I was on my way home after a RG500 track day in Taupo, and boom.

I need to fess up, that there bearing is a new one from my last strip and rebuild. Only bearings and seals were done due to wife shopping habits.
That rebuild was done due to that there dam bearing which collapsed and caused the gearbox to seize which in turn made the bike stop quickly, which in turn freaked me out, which in turn had me standing on the side of the road some where near the middle of the major highway from Taupo to Te Awamutu. It was such a major highway that there was about 1 car every half an hour and no mobile coverage. Great.

So that bearing fits like a roger is a 25yr old, used but not flogged. Not interference fit..... like a __old

Loctite might work with some new stuff and proper prep. Its not to far gone like a 45 yr old that can catch a sock sideway. There is no slop (excuses the pun) its just has spun enough to fuck the interference tolerance. Mate say dot punch, Loctite and shut up!

Anyway pulled the motor to bits and replaced all bearings and used Loctite on that dam bearing last time which obviously did not hold. Obviouly not enough care and the Loctite was like 20yrs old. Thanks to my last job.

few more beers and more parts created.

http://i982.photobucket.com/albums/a...psca5521fe.jpg
Love that stand... the bottom of the motor.

Water pump.

This here gear transfers all the power from the twin cranks are applied it to the output gear shaft.

Rock the long bolts back and forward, do not use a hammer or screw driver to remove this, other wise it will end in tears...

Job done.

Right we need to move the shaft and push the bearing out. It is not a tight fit but it helps 150% if you heat it up to remove the bearing and remove the shaft... heat it up to hot to touch seems to work well.

The shaft is bored out with a solid end inside the shaft, so use a long bolt to tap the shaft, DO not bash the end of the shaft or there will be more tears....

Bearing removed and now the shaft can be removed. The aim is to use the hammer just in a threating way not to bash.

everything ready to be removed.

**Arronduke** · 3rd July 2014, 22:23

I want to re anodize my swing arm as powder coating is not right, it is to thick...

Can it be done ? everyone says NO. result will be shit.

powder coating is not right to thick so painting might be an option...

And no to the word polish, gay people come to mind.

So what say you all?
"Dude I have a new swingarm you can have it!" .... that's a good answer!

Run out of funds again for the moment, spent to much on the GSX1100EZ

and that's two projects away.
Kat 1327 is next

...........! then the EZ. Hell need to finish the RG. But the EZ is going to be cool... upside down forks, 6 pots, bandit swingarm etc... yep in the shed.

back to the RG...Got most parts just need to pay for the labour to rebuild the cranks and then bore 4 cylinders. I have the parts ready to go to rebuild.
Oh did I mention the wife wants to know where all the money is gone? and if I spend any more than $15 I have to ask.

What is to be come of me with these new rules.?

**Arronduke** · 3rd July 2014, 22:28

OH and NO I have not sorted the bearing thing.!

I'm sure it can be done for less than $15... just might be a few instalments!

**Ocean1** · 3rd July 2014, 22:32

You can anodise it, it won't hide any nicks or scratches though, better to get it soda blasted first.

Makes the surface a bit harder too, little more abuse resistant. Not sure who you'd get to look at it up there though.