fakhir

The real challenge now is to clean it

Summary: Well this is it for now. I hope you enjoyed the pictures and videos. I've opened up and disassembled clutch, gear and kick assemblies. Generator assembly has also been drilled out. Next time I will try to further rip up the engine covers and hopefully gain access to the entire camshaft assembly. Stay tuned for the next episode. Bye for now !!!

Videos: (720p HD) It is highly recommended that you watch these videos in fullscreen HD mode. They've got pretty high resolution. http://www.flickr.com/photos/fakhir/9138629640/ http://www.flickr.com/photos/fakhir/9136714157/ http://www.flickr.com/photos/fakhir/9137060105/ http://www.flickr.com/photos/fakhir/9136817903/

Old picture:

Finally borrowed a drill: My good old trusty point and shoot camera: YB100 manual. Keep it handy at all times !!!

IMP: Following pictures (and movies) are taken by my brother using his awesome DSLR 60D camera. You can check out his other non-related but super cool pics and videos on his personal blog: http://farhanshaheen.wordpress.com and here: http://www.flickr.com/photos/popat

You wanted to know what "Hell" looks like? Well, it looks like this:

Week 4 updates (26-June-2013) Hey, I hope all of you are doing fantastic. Well it's been a while since I posted anything on the forum, been a bit busy. This time I was successfully able to tear apart the exterior engine hull and disassemble gear, kick and clutch assembly. Right now stuck with the cam shaft and piston assembly. Next time I will try to completely open up the remaining engine parts. Sorry no descriptions on the pictures this time. I will add those later on. Enjoy !!!

You are right, I will probably get a new connecting rod and piston. Thanks a lot

Thanks, I will try it out. One more thing: How do I get the piston pin (wrist pin) out? I've already removed both of the circlips that hold the pin. But it is really stuck in there, I even tried to hammer it out softly (potentially ruining the piston LOL ).

In case if I drill the screw heads off, will the engine block come off easily? I mean the shaft threads pass through block 1 and then into the second block. If head is gone, how am I doing to separate the engine blocks? The shaft threads are locking BOTH the engine casings/blocks right ?

Concluding Week 3 Ok people, this is it for the week. At this point I am totally stuck, I don't know how to get those screws off. Following are some strategies I had in mind: 1) Heat areas surrounding the jammed screws using some kind of propane torch. 2) After that apply loads of WD-40 in the expanded areas and leave it there for a day or two. 3) Use a proper sized '-' or minus bit on the impact screw driver instead of '+' bit, drill a little bit '-' grooves and try minus impact driver again on the deformed screws. 4) I am not sure about using the hammer and chisel technique but that is also one option, I mean what ever that gets the screws off of the engine. 5) If still I can't get these open, I might have to borrow a drill from somewhere and try to drill out the deformed heads. That will hopefully detach the two engine blocks. In this case, will the front engine block come off easily while leaving screw shafts inside the other engine block? More work will have to be done to get the shafts out. 6) I REALLY hate to say this, but last option: "Take the engine to the mechanic " Question: If I apply option 5 (drilling the screws), what would be the worst case? Will I have to buy a new yamaha engine? If heads are drilled, I assumed that the shafts will still be in the casings, is it possible just to replace one of the case (other case should come right off as soon as screw heads are gone)? Edit: I forgot to mention that the piston wrist pin is also stuck! Thanks a lot for viewing. See you next week with more pictures and updates

Some more damaged nightmare. Way too much rust and deformed screws, nuts and bolts. I mean: Give me a break. This is my first ever project !!!!!!!!!!

Then I applied WD-40 and left it there for around 7-8 hours. Then I used impact driver again, some of the screws came off with a bit of working around. But few screws got soft and further deformed due to the high torque impact driver. I also hammered the area surrounding the screws but failed to open them up (using a hard wood of course. DO NOT use metallic hammer on the case directly) Closeup:

Hitting brick wall (totally deformed screws): Ok so i've hit the brick wall. There are a few screws which are horribly deformed to such an extent that there is no way I might get them out without any physical damage to the casing: I first tried impact screw driver. But the screws were totally jammed, rust won this time. Since screws were already deformed and soft, impact screw driver probably damaged them a bit further:

Got drifted away LOL. Wooden plank closeup: (This is oak wood i guess) Closeup: Okay, enough of the wooden plank closeups... Moving on...

Point system: Some of the screws are in excellent condition: Some screws are in a horrible condition, thank you Mr. mechanic: