OK... here's more photo's. I'm sure that all of this is very familiar to you experts, but its new to me... so I'm sharing.
What's really interesting is trying to photo-document the process. Props to you guys who always to that.
Here are the photo's:
Here's a repost of the poor man's leak down test pics
Here is the removal of the flywheel nut. Its an 18mm. I've learned my lesson about using 12 point sockets. They can strip. I only use 6pt sockets now.
Notice the "poor man's" engine lockup tool, which is a small piece of wood wrapped in plastic cause it was dirty. What you can't see is that there is another small piece on the front side of piston. This works perfectly.
Here's the removal of the flywheel using my ebay flywheel puller and the same 18mm socket and a crescent wrench. Be sure to get the correct puller. There are different ones to get based on which year bike you have. Notice how I used the foot peg for leverage. I had to put a little muscle behind the socket and it gave out a loud snap before the flywheel slid off.
Remove the flywheel and the gear behind it and you can see the cam chain and the rear cam chain guide. They are both easy to remove.
IMPORTANT: There is a little "dowel pin" (if that's what its called) that goes between the flywheel and the crank shaft. It aligns the flywheel to the correct position on the shaft. I didn't know it came off until it fell on the ground when I removed the flywheel. Its very small, so look for it. Its going to be needed for reassembly.
(edit: that "dowel pin" is actually the woodruff key. It aligns the flywheel to the correct position on the crank. Its very important)
Notice the old and new cam chains. The new one is on the bottom next to the screw driver. They are the same lenght and it hasn't been stretched or anything. Oh well... I'm going to replace it anyways. I already got the new one.
New cam chain installed. I had to remove the bolts from the chain guide. I put a little blue locktite on the bolts before putting them back in.
Here's the removal of the clip on the piston. Why doesn't 2 strokes use snap ring clips like this? It was too easy!
Here's the removal of the piston pin. I gave it a slight push from the other side before pulling it out.
Here is what the skirt on that piston looks like after over 6,000 miles. Not too bad. It wears nicely. I'm replacing the piston because I already got the kit. But next time, I'll pull the piston and check it out first. I think I could have easily cleaned up and reused this and saved the $100.
Now its time to clean the old gasket off the case to start the reassembly
More pics later when I do more...
Click here for part 3 and more pictures
Edited by mauricedorris, April 09, 2010 - 07:07 AM.