So last year my cam side crank bearing let go I am hopeful that was the extent of the damage. I had ordered all the parts for the job from Dan at Motoxotica however found out today he is waiting on more bearings:( I will be posting pics and updates and hope to get it done by the end of June. Hopefully this may rev up some more chatter about these bikes I live in the willywags of Vermont and not a soul has heard of Vor! Anyhow any feedback/tips on tearing this motor down would be greatly appreciated as this is my first time with this motor. I am thinking I will have to fabricate some sort of case splitter. I was also toying with the idea of pulling the cyl and head off as one unit anyone done this before. I have a new head gasket on the way soon but part of me wants to save it for an emergency when there are none left! Thanks guys.

Edited by VTvor, 30 May 2012 - 05:28 PM.

If anyone is interested in how to coax these motors out of the bike I just removed mine and found that you can get it out by lifting the front till the head hits the frame then pull the back above the swingarm (3 inch long 1/2" extentions work great to replace the swingarm bolt without blocking the motor) once clear pull the back to the right tip head to left wiggle some more and she wil come out the left side. Also I found that it is much easier to take the oil line off the head as well as the oil breather fitting on top of the head. I asked this a few months ago and the reply was something like lots of wiggling hope this clears it up for anyone.

Sounds like a fun project!

You should post some pics as you go.  I don't think many people (myself included) have seen the inside of those beasts.

I hope to post pics by this sunday. Will be spending all day on Sat getting it torn apart as long as I can fab up a case splitter. I have a few things for other bikes so hopefully it wont be to hard. I will also do my best to post the specs on the splitter I build maybe that will help the next guy without one.  And ya this Vor is a beast when its running its like a dream feels almost like a Deere tractor almost no powerband its always ready at a twist. Wife is happy to have it out of the livingroom though! Anyone out there have a link or pdf copy of the 04 en-mx spare parts manual been looking everywhere but no luck so far?

i  take  it  dan  has  no manuals  ??   is there one   that  can  be  downloaded  from  italy  ??  just  wondering  if  it  would have  an  english  version  ???

He may have one I have not sent him an email asking though. The vor-club web site lists one but I cant seem to download anything from there. I did send them an email request a bit ago but have not heard anything back something tells me with the lack of much Vor activity they dont check that email often. Not sure about english in the 04 parts book but I have the 3 ring bound shop maunual and the paperback for 02 and it is in english and italian. I got those from Don Knight I think years ago when we imported a 530mx and my en-e450 in 02.

Ok found the manuals and a few links for them by searching in Italian. Made another post about them and will put the links there now on to the fun and sad stuff!


Safety First!


Pre Strip


Cam gear cover removed note there are no timing marks whatsoever I later painted some with white out but plan to engrave better ones later.


Looking in from exhaust side you can see the cam lobe for the intake is a bit chewed up cant see it here but the roller on the rocker also had some pitting:(


Transmission cover removed the book says to use a puller but I used some very small pry bars and a rubber mallet came of pretty easy

Stator cover and e-start gears removed (this is when I found out I had the wrong flywheel puller)


Clutch removed notice the star wheel on the shift drum I had to take that of to pull the sift drum out gonna be fun figuring out the alignment when it goes back in there was no way to mark it gonna be one of 5 or 6 possibles:(


A valve you say?? nope its the clutch push rod! I think the brothers had some older valves floating around and used those! This got some chuckles anyone seen this before?


Made these marks found the best spot with no tension on the valves at least this way no matter what happens as long as they are all in line it will be timed the way it was.

Cyl removed wow that factory case sealer goo is tough I kept the 2 upside down bolts in the head and took it all off as one unit hopefully not warping the head in the process. Looks like she was running a bit rich.


I love the V on the con rod!


Very crude case splitter but worked like a charm will be taking the measurements later and adding them in case someone needs to make one.


Case split fairly easy had to give a few small raps on the kickstarter gear to free up the back.

Notice the missing balls in the main most got chewed in the motor:(


Parts Parts Parts



Now for the fun stuff waiting to hear from motoxotica to see what he has. Found a few places in Italy that have a lot of stuff but waiting to see what Dan can come up with.

  I've always wanted to see a close up of the gear drive--way cool!

That push rod is hilarious I would have never guessed it was anything other than a valve lol.  

Hope you can find what you need looks like a really fun project.

Actually I just finished up the motor last week and got it in the bike this past sat. Beast fired 3rd kick:) Still working out some jetting issues and a small oil leak at the head. Will be posting pics of the install as soon as I get some time. Way things go that could be a few weeks found some intersting stuff in there though.