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Mar 11th 2017, 07:48 PM   #1
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
Decided to rebuild (image heavy)

So I guess I'll start from the beginning, kind of.

I got the GasGas a while back. I like it, but it is kind of a pain in the ass. "Exotic" is a good word to describe it; can't get parts for it, they're expensive when you can and no body know jack shit about them, at least these 4T bikes.

When I got it I knew that I needed to get new chains and sprockets, pretty par for the course with older bikes. I put it off after I cleaned it up and I ripped her around for a while.

Friend and I decided to head up Naches Pass. Bad idea it turns out. Well not really, I just neglected to do any maintenance and went up with a loose chain. Mistakes were made. Loose chain + bumpy road =





Video:https://youtu.be/D6_eUTDj6SM

Good thing we drove up in the truck.

Broke 7 of the 13 teeth on the front sprocket and the kick stand mounting bracket. So naturally, I replace front and rear sprockets and the chain. While I was at it I fixed the "kick stand of death." It automatically retracted, I did no appreciate this feature.

This process was not without it's difficulties. I broke one of the rivets and hand to get that replaced.



About a month later, I ended up having to replaced the starter clutch.



This was a BITCH. Remember what I said at the beginning about parts. Yeah... this was stupid. The GasGas part is over $400 for the sprag gear, oh hell no. Luckily someone over on the GasGas Rider Forum has had this issue before. I contacted the manufacturer of the sprag gear (Ringgspan) and they gave me an updated part number. I had to order this through a industrial supplier in Tacoma, Motion Industrial, but it was less than half the price of the GasGas part. WIN!

While replacing the starter clutch, I decided to check the valves. I was having starting and idle issues hence new starter clutch. They needed an adjustment. No big deal. Famous last words.

This is where the real learning begins for this bike. Many hours spent on forums, comparing parts fische and maintenance manuals leaves one conclusion, from the jug up this is a DRZ copy and the bottom end is a CRF copy. Kind of. The reason I had to do all this digging is because GasGas inexplicably did not put certain tolerances (valves clearances) in the service manual.

When it's all said an done I have the valves in spec, new starter clutch installed. Let's ride. I fire it up and putt around the neighborhood. Satisfied I head over to a new housing development nearby. As I turn around to head home I here a loud band and the bike dies. FUCK! Won't start, double FUCK! I get to push it home, yay. I take the shortcut across the field which is still a little over 3/4 of a mile to the house. Once I get back I put it on it's stand and walk away. I'm pissed.

Two months later I decide to figure out what's going on. Remove the body work and tank, all of which I'm very proficient at now and go for the valve cover. I figure I must have adjusted the valves wrong or something. Intake valves are in spec, right where I left them. Exhaust. First one is a bit loose. Alright, weird but I can deal with that. Second one, no clearance. Hmm... Pull cams and I notice it right away. Spring is up too far.

I start to pull the head. First thing is to remove the header. As I'm working the pipe away from the port I can hear something metallic banging around inside the pipe. Pull it off, it's part of a valve.

Finish removing the head and this is what I see.





Boy did that broken valve do a number on the head and piston. After closer inspection I also notice this:



Turns out I must have mis-timed the exhaust cam. The result of which is one detonated valve the other bent and a jacked up head and piston.

I ask for advice here on the forum (I appreciate everyone's input) and ultimately decide that it's less expensive to rebuild.

Now for the "fun" part, sourcing parts. I ended up finding the piston and head gasket NOS on eBay for about half the AOMC was asking for new ones. Yoenk. Bought those in a heart beat. Sourced them from Greece. They came in a cool old-timey packaging.







Only took like ten 1.50 euro stamps to get it here.

I was able to source a replacement head from a GasGas dealer in Nova Scotia, Canada.

The rest of the parts for the top end I was either able to get from Tacoma Motorsports or order from ktm-parts.com (AOMC). Turns out it wasn't that simple though. I ordered a few seals, base, valve cover, clutch cover gaskets and a few other odds and ends from AOMC. A couple weeks later I got notice of partial shipment. I called them up worried about the base gasket in particular and they assured me that I will get them, just didn't know when.

During this time I had got the replacement from Canada and was working on getting it up to snuff.

I "fabricated" this part to help me remove and install the valves "properly." I took the Dremel to a spark plug socket that I never and will never use. Fits the valve perfectly.



Works pretty well with a adjustable clamp.





I started by lapping the valves to get a proper seal. Boy does this suck. I tried a couple of techniques, by hand and with a cordless drill. I got the exhaust valves to seal well, but I couldn't get the intake to seal. I know when I'm beat and my skill is exhausted, so I broke down and took the head to Woody at Action Cycles in Tacoma. The nest day he called me and told my the valve guides need to be replaced before he could cut the valve seats. Why not another thing I guess? Ordered those from PDI because the Kibblewhite guides are a third the price of OEM Suzuki and I don't know how long it would take to get them from GasGas. Shipping was quick and I got those to Woody this week.

I called AOMC again this week to ask about the base gasket. Rep informed me that they had received them and he would get them sent to me ASAP. They ended up overnighting them to me which is awesome, but at the same time I placed that order 1/27.

Hopefully, I will have the engine back together next weekend. WOOT!
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Mar 11th 2017, 07:53 PM   #2
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
Today I ended up removing the clutch and installing the piston on the CR in prep for assembly.





The friction plates were pretty worn. I'm glad I'm doing that too.



New friction plates are soaking in oil overnight tonight and I'll install those tomorrow. These are actually '92 CR250R clutch plates. They're a little thicker than the stock GasGas kit, but you can compensate for the added thickness by replacing the trust washer behind the basket with a thinner washer from Suzuki.
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Edited by equinity on Mar 11th 2017 at 07:58 PM
Mar 12th 2017, 01:10 PM   #3
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
Please God, when will it end?



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Twistedracer likes this.
Mar 14th 2017, 11:07 PM   #4
 Reaper Rides's Avatar
 
  Mar 2017
  Woodinville

  09 Triumph Daytona 675
Good on you for deciding to rebuild rather than bail out on her. Great thread and pics.
Mar 15th 2017, 04:07 PM   #5
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
Installed a helicoil last night to fix the stripped threads and got the case back on. Thankfully the gasket was in good shape.



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Mar 15th 2017, 04:09 PM   #6
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
Quote:
Originally Posted by Reaper Rides
Good on you for deciding to rebuild rather than bail out on her. Great thread and pics.
Thank you. I like to tinker and all of my knowledge up this point has been theoretical. It might be weird to say, but it's been fun.

Sent via SM-G930V

Edited by equinity on Mar 18th 2017 at 07:20 PM
Mar 16th 2017, 06:52 AM   #7
 Wrench's Avatar
 
  Jan 2016
  West Richland, WA

I know you already made your own, but these work good and are inexpensive:

https://tboltusa.com/store/valve-spr...ool-p-935.html
Mar 16th 2017, 03:21 PM   #8
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
Quote:
Originally Posted by Wrench
I know you already made your own, but these work good and are inexpensive:

https://tboltusa.com/store/valve-spr...ool-p-935.html
It's good to have the correct tools though.

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Mar 16th 2017, 03:24 PM   #9
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
I just got an update from Woody at Action about my head, turns out the intake valves are bent from the "new" head. I imagine that's why I couldn't them to seal. Hopefully the valves from the old head are in good shape.

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Mar 16th 2017, 04:23 PM   #10
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
Old valves are good. Woohoo!

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Mar 18th 2017, 12:50 AM   #11
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
I've got head!

Lol



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Mar 18th 2017, 12:51 AM   #12
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
Coming along.



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Mar 18th 2017, 03:38 PM   #13
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
Almost ready for fluids.



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Mar 18th 2017, 07:21 PM   #14
 equinity's Avatar
 
  Jan 2016
  Puyallup

  Yamaha FZ1, Aprilia RSV4 R
IT LIVES!!!

https://youtu.be/oV9drTQ9POM
Mar 20th 2017, 02:44 PM   #15
 Reaper Rides's Avatar
 
  Mar 2017
  Woodinville

  09 Triumph Daytona 675
Quote:
Originally Posted by equinity
Thank you. I like to tinker and all of my knowledge up this point has been theoretical. It might be weird to say, but it's been fun.

Sent via SM-G930V
Not weird at all. I love doing all my own work. There's no better teacher than experience and nothing better than the sense of accomplishment.
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