Have started this this morning as have been away for a week. Have removed a fair amount of the bits i need to (oil drain plug has a fair amount of metal filings magnetised to it). One that has stumped me are the two screws holding the plate in place that hides the thread where you use the casing puller. They are done up so tight and the metal is so soft that they are now losing their shape so a screwdriver now won't fit with any purchase. Am I going to have to drill them out?
Don't drill them unless you really have to mate. Get a centre pop and work around the flange. Even better, use an impact driver obviously taking the whacking bit easy.
@ducati dad Does your case removal method mean I can leave the plate on that now has my threaded screws?
Yes it does. If you can punch around one screw out on the crank cover, as mentioned by bettes and remove it, you can then tap the little cover anticlockwise to loosen the other screw. I would not be using an impact screwdriver, as it would probably crack the cover. Don't know why you have Phillips head screws in there, they should be c/sunk Allen heads.
Thanks. I did wonder about those screws, they did look out of place when everything else is an Allen key. I've ordered a damaged screw head removal kit with Amazon Prime so will hopefully get them both off when i work on it again tonight.
You could use a large drill just to remove the heads, then with the cover off, unscrew the threaded part with some Molegrips etc. Although there may not be much left sticking out.
If they are Phillips make sure you are not using a Pozi driver, they don't mix right. And vice-versa. Have you squirted some de-grip on them?
Always remember heat is your friend. As said before. If it's not moving. Then the drill the head off with a slightly over size drill bit. But make sure your bang on centre.
Ordered this gizmo, what a great thing. You drill into the screw head with one end (drill in reverse) then flip the bit round and still n reverse the fat end locks into the damaged head and out it comes.Took all of 5 minutes to do the two screws and one Allen key bolt. https://www.amazon.co.uk/gp/product/B01E9ZC2K2/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
Have got the engine casing off now and found a few of these slithers of metal in there, but aside from that everything looks hunky dory to my untrained eye.
Got up early to put the bike back together thinking there was nothing wrong with it and after a second look discovered where (hopefully) the odd noise and metal shards came from. On this image (taken from Northan Monkeys picture) you can see the little arm with two 'prongs' on it, which slot on to the arm near the stator - on the second image of my engine you can just make out one of mine has snapped off. Found it at the bottom of the engine while i was having a wipe around. So my next round of questions are: what is that part called? how do i replace it? online free photo storage online free photo storage
Oooo. Interesting. It's tricky to see from that angle. But if part of the slot drive is missing. Then as Bootsam said water pump drive is fubar. And obviously you need to find the rest of it. If your not aware that's also the Cam belt drive shaft.
Thanks gents. It does look like it goes through the casing and out the other side (rhs of the bike) so could/does turn the belt. I do have the part that fell off, and the whole thing slots into the bit at the top of this image: https://ibb.co/cWqC9F Am i right in thinking then that i need a cam belt drive shaft, where on the bike is the water pump drive?
Hate to be the bringer of bad news but as NM says it also drives the camshafts and has the lower belt pulley on the other end, it is called the timing layshaft. Unfortunately it will need a complete strip down to replace it. It is item 3 in this pic from the parts list.
