Announcement

Collapse
No announcement yet.

2003/1600 Engine Disassemble

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • 2003/1600 Engine Disassemble

    Hello all! I hope everyone had an enjoyable Christmas and New Years. Here in Canada we hibernate in our homes and are unable to ride until April/May. Unfortunately, last summer i lost 5th gear on a trip through Northern Ontario. It failed at the 200km point into a 1000km trip. She got me 800km home in 4th gear. I strained the oil and nothing come out. Now its time to repair it. I'm using a Clymer service manual and its going well. Step by step instructions and very detailed. Once i get into the transmission and find out whats broken, i'm rebuilding with new rings, gaskets and a Barnett clutch. I noticed the cylinder walls have some scoring and plan on sending them out for a hone. I also noticed a considerable amount of carbon build up on top of the pistons. Does anybody have some suggestions that i should be replacing or inspecting? Cheers!
    Attached Files
    "It's not the destination...it's the ride"

  • #2
    Do not hone the cylinders! They are coated with a ceramic type material that is bulletproof and contributes to the longevity of the engine. Make sure you have the upgraded oil pump gear.

    Comment


    • #3
      The 2003 does not need the oil gear changed. It was fixed earlier.

      Comment


      • #4
        If the cylinder walls really look bad, you have 2 choices: Replace the cylinders or go with a big bore kit. Patrick Racing is the source.There's a set of stock 1700 cylinders and pistons on Ebay for $199.99. IDK if the swap is possible but others may. Good luck.

        Comment


        • #5
          Can you show a picture of that scoring, I've never seen it happen on a 4 stroke with ceramic composite coated cylinders. 2 strokes yes but never a 4 stroke, my 650 had 70,000 miles and i could still see some factory honing marks in the cylinders when i replaced 5th gear. I had the 30,000 roadstar apart last year and those cylinders looked brand new, if the ceramic got scored i can only imagine what the piston skirts look like

          Comment


          • #6
            I used nylon bottle brushes and solvents to remove carbon from the pistons and combustion chambers on mine, there was so much of it the engine had some spark knock and when trying to start it hot it sounded like the timing was too far advanced, after cleaning it up it never did that again, there was so much carbon i couldn't see the valve relief in the pistons on mine

            Comment


            • #7
              Don't Hone cylinders.... Clean with rag and brake cleaner

              If using Barnett pressure plate makensure to use only OEM Yamaha clutch disc's and steels (not Barnett clutch disc's and steels)... Also good idea to get rid of the wire and half clutch disc behind it and replace will a full size one.

              Can carefully scrape carbon deposits (get big hunksnoff
              Loosing 5th gear is very unusual.... What all happened? What oil has been used? What mileage on bike? How long have you owned bike?
              LET'S RIDE

              Comment


              • roadiemort
                roadiemort commented
                Editing a comment
                Sounds more like slipping real bad in 5th?

            • #8
              Originally posted by Pauli466 View Post
              Can you show a picture of that scoring, I've never seen it happen on a 4 stroke with ceramic composite coated cylinders. 2 strokes yes but never a 4 stroke, my 650 had 70,000 miles and i could still see some factory honing marks in the cylinders when i replaced 5th gear. I had the 30,000 roadstar apart last year and those cylinders looked brand new, if the ceramic got scored i can only imagine what the piston skirts look like
              I found out its not scoring. Just up and down marks. Can't feel it with a finger nail.
              Attached Files
              "It's not the destination...it's the ride"

              Comment


              • #9
                I'm here now and there is definitely a problem in the transmission. Shifting through the gears at this point and still no 5th gear. Lets get this case open.
                Attached Files
                "It's not the destination...it's the ride"

                Comment


                • #10
                  Originally posted by Lug Nut View Post
                  Don't Hone cylinders.... Clean with rag and cleaner

                  If using Barnett pressure plate makensure to use only OEM Yamaha clutch disc's and steels (not Barnett clutch disc's and steels)... Also good idea to get rid of the wire and half clutch disc behind it and replace will a full size one.

                  Can carefully scrape carbon deposits (get big hunksnoff
                  Loosing 5th gear is very unusual.... What all happened? What oil has been used? What mileage on bike? How long have you owned bike?
                  Thank you for the clutch and cylinder info. From what i've read there was an issue with the 2003 R* 5th gear other than the circlip recall. I was riding along and shifted from 4th to 5th and the shift didn't feel right. it felt like a soft "crunch" so i let the clutch out and nothing there. It reved up like i was in neutral. Pulled over and stopped. Started off again shifting through the gears perfectly, until i shifted into 5th and again nothing there. I've always used Yamalube 10W-40 and never had a problem. The bike has 67,000 km (42,000 miles). I've owned the bike for 3 years. I'm not sure how the previous owner rode, but i do know he did ride 2 up. I usually ride 2 up with luggage and have to admit i've lugged it a few times in 5th. An 18 year old bike i think she needs some attention.
                  "It's not the destination...it's the ride"

                  Comment


                  • #11
                    Originally posted by Shores View Post
                    Do not hone the cylinders! They are coated with a ceramic type material that is bulletproof and contributes to the longevity of the engine. Make sure you have the upgraded oil pump gear.
                    I had no idea they are coated! Thank you!
                    "It's not the destination...it's the ride"

                    Comment


                    • #12
                      Just a little update...I've got the case open and found this. Dogs broken off 2nd/3rd Pinion.
                      "It's not the destination...it's the ride"

                      Comment


                      • Duke
                        Duke commented
                        Editing a comment
                        Make sure you don't lug the engine in any gear. If your getting chatter when twisting the throttle, you would be in "to high of a gear".

                    • #13
                      Looks like something had to give. And that is the result!

                      Comment


                      • #14
                        Originally posted by Sharpman66 View Post

                        I found out its not scoring. Just up and down marks. Can't feel it with a finger nail.
                        That's the crosshatch honing, those cylinders are like new, don't remove the carbon ring from the side of the piston, that carbon ring helps control oil burning

                        Comment

                        Latest Posts

                        Collapse

                        Topics Statistics Last Post
                        Started by AZRoadie, 2 days ago
                        16 responses
                        115 views
                        0 likes
                        Last Post AZRoadie  
                        Started by roadiemort, 6 hours ago
                        3 responses
                        54 views
                        2 likes
                        Last Post Father Pobasturd  
                        Started by LDofDC, 12-23-2020, 12:17 PM
                        127 responses
                        693 views
                        0 likes
                        Last Post roadiemort  
                        Started by whale2455, 18 hours ago
                        3 responses
                        83 views
                        0 likes
                        Last Post Tykes_Place  
                        Started by Jaybo, 6 days ago
                        34 responses
                        289 views
                        2 likes
                        Last Post Shores
                        by Shores
                         
                        Started by JayPee, 18 hours ago
                        5 responses
                        53 views
                        0 likes
                        Last Post roadiemort  
                        Started by Jinro, 1 day ago
                        7 responses
                        116 views
                        2 likes
                        Last Post Jinro
                        by Jinro
                         
                        Started by $arleysSuck, 21 hours ago
                        9 responses
                        69 views
                        0 likes
                        Last Post Horsehammerr  
                        Started by Madmichaeld, 20 hours ago
                        7 responses
                        46 views
                        0 likes
                        Last Post Father Pobasturd  
                        Started by Doc_V, 09-23-2020, 02:48 AM
                        92 responses
                        1,595 views
                        1 like
                        Last Post davej
                        by davej
                         
                        Started by NthernLgts, 4 days ago
                        11 responses
                        183 views
                        0 likes
                        Last Post NthernLgts  
                        Started by roadiemort, 6 days ago
                        8 responses
                        115 views
                        0 likes
                        Last Post roadiemort  
                        Started by Madmichaeld, 21 hours ago
                        1 response
                        42 views
                        0 likes
                        Last Post Father Pobasturd  
                        Started by Peterboro Pete, 2 days ago
                        11 responses
                        66 views
                        0 likes
                        Last Post Chromepony  
                        Started by AZRoadie, 2 days ago
                        4 responses
                        107 views
                        0 likes
                        Last Post Chromepony  
                        Started by AZRoadie, 1 week ago
                        12 responses
                        258 views
                        0 likes
                        Last Post AZRoadie  
                        Started by Shores, 1 day ago
                        2 responses
                        38 views
                        0 likes
                        Last Post moose
                        by moose
                         
                        Started by Jinro, 12-08-2020, 06:02 AM
                        19 responses
                        511 views
                        10 likes
                        Last Post Ironman
                        by Ironman
                         
                        Started by MikeyC, 1 week ago
                        13 responses
                        112 views
                        0 likes
                        Last Post MikeyC
                        by MikeyC
                         
                        Started by BrokenWheel, 1 day ago
                        8 responses
                        61 views
                        0 likes
                        Last Post BrokenWheel  
                        Working...
                        X