'01 engine assembly

fixxervi6 · September 10th, 2012, 04:06 PM

Hello, I have an 01 engine that I split open, thinking it was going to be trash.

When I pulled the case bolts to split the case I just threw them all in a bag, I didn't keep track of where I pulled them out of.

I split the case and the problem turned out to be very simple, fixed the problem (gear problem in the transimission) and now it's time to reasemble.

Anyway, I have the service manual that gives me the torque specs, but not all of the bolts are the same length, I need to find something that will tell me what length bolt goes in which whole.

Also, the book says to use liquid gasket, but it doesn't say how much to apply, will any type of liquid gasket do?

thanks in advance

choneofakind · September 10th, 2012, 04:11 PM

paging @Racer x, the engine guru

and alex.s!!! sorry dude! I completely forgot that you've had your case open

alex.s · September 10th, 2012, 04:16 PM

use kawibond

there are only 2 bolts that fit in multiple holes, and they are in the oil pump (the shiny allens, there are 3 different sizes and they can be used interchangibly except for the long ones can only be used in the long holes. its easy to mix those up.

basically, the thicker bolts go on bottom, the thinner longer bolts go on top, the smaller thin bolts go along the perimeter and on the covers. dont forget the bolts inside the oil filter slot

Racer x · September 10th, 2012, 06:29 PM

Alex has it
As for sealant. I use Honda bond . But not much. I clean clean clean the case half's. Then smear a VERY small amount of the gray sealer on the top side.

I put it on very thin and kinda rub it on. Using the sealer almost as a cleaner. You can see if it is sticking to the case half. Always wiping it off the edge or inside the case. After is sits for about fifteen minutes. I then put the bottom on and bolt it down. There are a number of things like the oil feed pipe that fits under the stater. And the shift fork that tangles in there making the assembly a bit tricky. You might want to try a dry run.

What you don't want is sealer squeezing into the case. The extra sealant breaks off in strings and clogs the oil pick up tube.

fixxervi6 · September 10th, 2012, 06:50 PM

Thanks guys, I'll give it a few dry runs.

fixxervi6 · September 19th, 2012, 07:07 AM

She's back together and she lives

I went to bikebandit.com and looked at their oem parts for the bolt pattern for the case, then just measured each bolt according to their parts list (parts list gives bolt size) and just threw them in based on the diagram, got it right on the first try.

CZroe · September 29th, 2012, 08:08 AM

I used Hondabond but switched to high-temp RTV sealant from the same company that makes Loctite. Seems to be what the service manual called for and I'm tired of manufacturers getting away with monopolistic practices like trying to force their parts, supplies, and tools on you.

jayman87 · February 22nd, 2013, 06:19 PM

Quote:

Originally Posted by CZroe

I used Hondabond but switched to high-temp RTV sealant from the same company that makes Loctite. Seems to be what the service manual called for and I'm tired of manufacturers getting away with monopolistic practices like trying to force their parts, supplies, and tools on you.

Is this what you were talking about.

http://shop.advanceautoparts.com/web...=high+temp+rtv

I bought this before I thought to look up what other people use.

http://shop.advanceautoparts.com/web...rm=ultra+black

CZroe · February 25th, 2013, 04:50 PM

Quote:

Originally Posted by jayman87

Is this what you were talking about.

http://shop.advanceautoparts.com/web...=high+temp+rtv

I bought this before I thought to look up what other people use.

http://shop.advanceautoparts.com/web...rm=ultra+black

Yep. I doubt the engine gets over 500-degrees so I'm sure they both work well.

September 10th, 2012, 04:06 PM	#1
fixxervi6 ninjette.org member Name: Rick Location: Texas Join Date: Sep 2012 Motorcycle(s): '01 250 '10 20 '09 GSXR 750 '97 KX100 '97 KX125 '06 GSXR 600 Posts: 24	'01 engine assembly Hello, I have an 01 engine that I split open, thinking it was going to be trash. When I pulled the case bolts to split the case I just threw them all in a bag, I didn't keep track of where I pulled them out of. I split the case and the problem turned out to be very simple, fixed the problem (gear problem in the transimission) and now it's time to reasemble. Anyway, I have the service manual that gives me the torque specs, but not all of the bolts are the same length, I need to find something that will tell me what length bolt goes in which whole. Also, the book says to use liquid gasket, but it doesn't say how much to apply, will any type of liquid gasket do? thanks in advance

September 10th, 2012, 04:11 PM	#2
choneofakind ninjette.org certified postwhore Name: . Location: . Join Date: Feb 2011 Motorcycle(s): . Posts: Too much. MOTM - Feb '13, Feb '14	paging @Racer x, the engine guru and alex.s!!! sorry dude! I completely forgot that you've had your case open Last futzed with by choneofakind; September 10th, 2012 at 08:11 PM.

September 10th, 2012, 04:16 PM	#3
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	use kawibond there are only 2 bolts that fit in multiple holes, and they are in the oil pump (the shiny allens, there are 3 different sizes and they can be used interchangibly except for the long ones can only be used in the long holes. its easy to mix those up. basically, the thicker bolts go on bottom, the thinner longer bolts go on top, the smaller thin bolts go along the perimeter and on the covers. dont forget the bolts inside the oil filter slot __________________________________________________

September 10th, 2012, 06:29 PM	#4
Racer x ninjette.org certified postwhore Name: Eric Location: Iowa City Join Date: May 2009 Motorcycle(s): 2008 Kawmeracchi 350 2010 Project X Posts: A lot. Blog Entries: 54 MOTM - Sep '18, Feb '16	Alex has it As for sealant. I use Honda bond . But not much. I clean clean clean the case half's. Then smear a VERY small amount of the gray sealer on the top side. I put it on very thin and kinda rub it on. Using the sealer almost as a cleaner. You can see if it is sticking to the case half. Always wiping it off the edge or inside the case. After is sits for about fifteen minutes. I then put the bottom on and bolt it down. There are a number of things like the oil feed pipe that fits under the stater. And the shift fork that tangles in there making the assembly a bit tricky. You might want to try a dry run. What you don't want is sealer squeezing into the case. The extra sealant breaks off in strings and clogs the oil pick up tube. __________________________________________________ Top speed 123.369mph. Ohio mile Worlds fastest 250 ninja

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September 10th, 2012, 06:50 PM	#5
fixxervi6 ninjette.org member Name: Rick Location: Texas Join Date: Sep 2012 Motorcycle(s): '01 250 '10 20 '09 GSXR 750 '97 KX100 '97 KX125 '06 GSXR 600 Posts: 24	Thanks guys, I'll give it a few dry runs.

September 19th, 2012, 07:07 AM	#6
fixxervi6 ninjette.org member Name: Rick Location: Texas Join Date: Sep 2012 Motorcycle(s): '01 250 '10 20 '09 GSXR 750 '97 KX100 '97 KX125 '06 GSXR 600 Posts: 24	She's back together and she lives I went to bikebandit.com and looked at their oem parts for the bolt pattern for the case, then just measured each bolt according to their parts list (parts list gives bolt size) and just threw them in based on the diagram, got it right on the first try.

September 29th, 2012, 08:08 AM	#7
CZroe CPT Falcon Name: J.Emmett Turner Location: Newnan, GA Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.	I used Hondabond but switched to high-temp RTV sealant from the same company that makes Loctite. Seems to be what the service manual called for and I'm tired of manufacturers getting away with monopolistic practices like trying to force their parts, supplies, and tools on you.