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Message started by justin_o_guy2 on 12/31/12 at 13:56:38

Title: Puttin it together
Post by justin_o_guy2 on 12/31/12 at 13:56:38

Finally got the parts together for the Grizzly 660. Yamaha sent 2 sets of rings that didnt measure to spec. A guy at the shop called the head office. They said " Ohhh,, we run them like that all the time. We dont have any problems with them.".. The gap on the compression ring was well outside the Max Allowable, which was almost double the high end of what the book called for in the "Normal,desirable" gap range. SO
Owner of the shop told one of the parts guys to get me whatever I needed to finish this job. The found an aftermarket piston .5 mm over stock, still 9/1 compression, wrist pin, rings, all that stuff & got it in for me in 2 days.

So, yesterday I started in on it Got the crank at TDC & tied the pull starter "crown" on the crank to pull starter cover bolts so it couldnt turn, tied the rod up & put the piston on it, lubed it all up good & worked the jug down & torqued it. Harder to put one together in the frame than get it apart, Ill Tell YEW!
Got the head on it last nite, some of those bolts are about impossible to get on w/ a torque wrench,, used a ratchet to get close with, then finished off with the torque wrench,.
My heart is still in my throat..I dont like this kinda work, at ALL.

Put the cam in today. Itskinda tricky. Its got some kinda decomp gizmo built in, springs & weights & kinda tricky..
Had all the dots lined up, mark on the crank & case agreed,, just one cam gear bolt in,, thot,, "Lets turn this thing around & see how it acts when it gets back to TDC.. ",, WoooHOoo! I am SO glad I did that.

ONE tooth off, the cam was lagging by one tooth, so, I re-did it.

Got it all back together, both bolts in, spun it again, using my finger as the cam chain tightener & it lines up Everywhere now..
There is exactly no way to get a torque wrench on those bolts. Says 20#, so, I stuck a socket in a vise & felt of 20# on the torque wrench. Built up a socket/ratchet & cheater bar & tried to replicate it as near as possible, cleaned the threads up in & out & used a drop O Blue Locktite.

Heart/Throat

I do not Like this kind of work,,,

Ohh, wait, I already mentioned that, didnt I?

I think Ill put the head cover on before I do the cam chain tensioner,,

Of course, Ill inspect the cam again before I do anything.
I came in to calm down, let my pulse settle back to normal. So, I thot Id just tell about whats been getting my pulse UP.. & I mean that literally. I am( well,, I was) actually shaking. I dont like doing things that have serious repercussions is its not right. Its not MINE & I cant Afford to pay someone to fix it if I mess it up.. & Its just scary to me.. I wish I was an arrogant, self centered, "I am never wrong" kinda guy some days.,

Title: Re: Puttin it together
Post by Ed L. on 12/31/12 at 14:20:06

JOG, if you were an alway right, never wrong type of guy you would of never found that the cam was one tooth off. You're doing good by being so nervious. Look at Custer, he never thought he was wrong and ended up getting scalped because of it. ;)

Title: Re: Puttin it together
Post by rl153 on 01/02/13 at 17:49:38

wow, impressive

Title: Re: Puttin it together
Post by Boule’tard on 01/02/13 at 18:38:23

627D7B7C61665767576F7D713A080 wrote:

My heart is still in my throat..I dont like this kinda work, at ALL.

It sounds like you've done your due diligence, and any further stressing out about it is not going to help your ATV. You very thoroughly looked both ways, it is safe to cross the street.. so trust yourself.

I know what you mean though, I felt exactly the same way when I had to reset the cam on that Husky. What a relief when it fired up normally! I am sure yours will turn out great too. [smiley=thumbsup.gif]

Title: Re: Puttin it together
Post by ZAR on 01/02/13 at 18:43:11

Gosh JOG, I'm still fretting over cracking open the Savage to check the cam chain :-[ . You da MAN!!!!!

Title: Re: Puttin it together
Post by ToesNose on 01/03/13 at 07:18:26

Keep us posted, and once the ATV is brought back to life we expect pics of you having fun!!! ;)

Title: Re: Puttin it together
Post by justin_o_guy2 on 01/03/13 at 10:59:25

Its not My Fo Wheeler. Its a Grizzly 660 a 78 Y/O man bought at a garage sale after some young fella rode the snot out of it for 350 hours. Air filter was disintegrated, motor had ingested dirt, valves had never been adjusted, I know that because of the marks on the adjusters, all of them had one line with dots at each end. I wont be riding it, Ill be sending it home. Poor dude thot he was buying a shiny new dime at a discount,,,& he was actually buying a total.,It was worth the cost of repair if he had taken it to the shop & had them resurrect it. But he paid about $2600.00 for it, THEN he ( well, I) discovered what was wrong with it,.

Ive got $928.00 spent on it just in parts & machine shop labor. He has paid $900.00, so, Im in it for 28,
Shop mgr at Yamaha told me that what Ive done so far would have cost about $2,500.00, maybe a bit more.

Title: Re: Puttin it together
Post by justin_o_guy2 on 01/03/13 at 23:33:01

Today, go the header in.. blasted gaskets kept falling out,, hadda glue them in w/ contact cement. Thatll stank a bit while it cooks out. TRied to lube the U joints,,must be some kinda super skinny grease gun tip to go in there,,,took the zerks out to swap them,, OOOPS,, hadda build a tool to put the one in the gun wouldnt grease..Got the exhaust all mounted, external oil line on the jug, carb mounted, geeeeze,, izzat ALL?? OHH,, fixed a coupla things around here,had a friend over & spent an hour on the phone to another friend,,AND I got up late,, & Ima do that again Tomorrow!

Title: Re: Puttin it together
Post by LANCER on 01/04/13 at 03:48:41

253A3C3B2621102010283A367D4F0 wrote:

WOW, you're having some fun now !! ;D

Title: Re: Puttin it together
Post by justin_o_guy2 on 01/04/13 at 08:00:54

Why Yes I Yam! &, If you show up Ill hook you up with a fresh cup O Joe & you can play, too. YOu have no idea how big a giggle it is to try to stab a header that has 2 ends that poke into the head & 1 that goes into the exhaust pipe end while supporting & aligning the exhaust & ATTEMpting to get & hold the 2 ends level & moving up & back & into the cavities in the head while not knocking those those gaskets loose. The angle doesnt exactly help them stay in. I was careful to not put glue on the surfaces that seal, but just a very small line around the edge on the back..

IDK what Im gonna do about gettin some grease in the U joint..I know IM not takin that zerk out again,,I hadda cross drill & slot a piece of brass tubing & stuff it in that & use the tubing to get it started. The spring that drives the ball up to close the zerk? It pokes OUT the back & ya hafta Push in & twist & the gap isnt wide enough to use a socket & it still be lined up so threads will start.Fun,Fun,Fun,, Yep, enough fun to share! Anyone interested in a Good Time, just stop by. Loads of thrills to be had. If ya dont wanna play with this one, theres the big wooden swingset/fort or the toilet installation job. I would let anyone clear the garden, & the ground is good & wet. Stuff otta pull real easy about now.

NOwhere on the planet can ya have so much fun for so little $$$.

Title: Re: Puttin it together
Post by Boule’tard on 01/04/13 at 08:17:39

Hey, where's that no-good nephew/son-in-law/young'n who is supposed to be helping you hold stuff in alignment? His fingers broke or something? Well at least you have some way of getting out of the weather.. no way am I getting out in this blustery muck to work on a bike. Carport and tarps = no thank you.

Title: Re: Puttin it together
Post by justin_o_guy2 on 01/04/13 at 08:56:29

The time of day I was doin the exhaust meant there was no one to help still awake, BUt, as a general rule, I dont go ask even if everyone is up & around. It doesnt even cross my mind. IM so used to solving my own problems alone that Im usually better off doing it that way. By the time I explain things to a helper & then worry about whether or not they "got it" Im happier just doin it,, besides, I kinda get a kick outta doin stuff by myself,

Title: Re: Puttin it together
Post by MShipley on 01/05/13 at 15:25:43

So, JOG, I need someone to go thru another motor I got.....Interested :)

Title: Re: Puttin it together
Post by justin_o_guy2 on 01/06/13 at 12:58:55

Lemmee think about it..

NO!~

Title: Re: Puttin it together
Post by justin_o_guy2 on 01/06/13 at 17:58:07

Welp,,, got her together enough to fire it up. Runs good at high RPM but requires some air inlet restriction to idle, so, I guess I gotta pull the air box & tank & get the carb on the bench & see whats in the way of fuel in the pilot circuit,, Blass TIT!
On the bright side, it RUNS!
Scared the poo outta me at first,, book calls for 2.1 quarts for an oil change, so, I did that, went a hair over & got it fired up, it coffed & sputtered a while & died. I checked the oil & it was a good bit low,, well, considering how long it ran, anyway..I thot it was ingesting oil somehow, but it wasnt smoking out the pipe like a mosquito fogger,,
Filled it up, ran it again, a bit low again,, so, added a smidge, ran it & let it sit a bit & Violas,, its all good. Sure didnt like the stuff I fo9und in the pan when I went thru the oil,, it had dirt in it & bits of metal the size of a fat grain O sand,., I wish I had the skill/knowledge/ability to have cracked the case & cleaned it out,but thats way past me,, They told me thats just an included step when they do a top end job at the shop, crack it open & clean it out & inspect stuff,,which makes sense, in that deep, sure would suck if in 200 hours some bearings "down in there" give up from the abuse that led to the need for the work Ive done,

Anyway, it Will idle, IF I gently lay my hand over the air intake & let the air fight its way between my loose fingers.,really its a very light restriction thats needed,,
Once I got to there I sealed off the intake & the big tube that feeds air into the belt & pulleys that make the transmission & fired up the pressure washer. Used the wimpiest nozzle & low engine speed & cleaned the mud out of the radiator core, went down a nozzle size & hosed the machine & belly pan parts & all the stuff thats off of it, cleaned out the mud from in the storage area, wiped it down, looks a Lot better than when it got here. REplaced a valve core on the rear. Cut a hunk of fishing line out that was wound around a rear axle.. just stuff that a decent, somewhat caring owner would do.. the kid that beat thing thing in the ground needs some teachin & his daddy needs a whoopin..