So a few days ago I purchased a 2006 DL1000 with only 18k miles on it for 1,800 greens.
The downside? The engine is busted.
PO managed to break the front cam chain, bent the valves and who knows what else went kaput inside that poor cylinder... so I'm calling that motor a complete loss... almost.
Anyway, I registered at here and posted my situation. Within minutes Snownut, who lives just miles away, PM'd me and told me something like "hey, I have a DL1000 engine sitting in my garage, other than a broken camshaft gear, it works nice and smooth." ;D
So I went, brought the engine home, cleaned it and inspected it.
The broken gear:
So now I just need to open the original busted engine, take the camshaft out, install it into the new engine and mount it on the bike.
Carefully inspect the valve guides where they enter the ports for any sign of cracking. With that much valve damage it is possible the stress of bending them has damaged the valve guides. Not always an issue but carefully look them over.
It's just the reflection of the light on the picture. Seat faces are clean and angle is OK.
Next steps: transplant from the donor engine the cam chain and the valves for the front cylinder... and cross my fingers.
Worst thing that can happen is that it doesn't work, so I'll go with plan B: Transplant the whole donor engine and ride to the sunset. In the meantime I'm learning a lot and having a blast :mrgreen:
Well, I was able to hold the rotor from spinning and get that chain gear out. I stuck a thick rag between the main rotor cogs and that stopped everything from spinning. Enough to loosen that chain gear's bolt.
Now, here you can see some crazy damage made by the broken chain.
Hey Off -- I just stumbled on to this thread. I had no idea when we rode last week that you were this far into the project! I really admire you for taking on this challenge. You have much more patience and tenacity than I have! I'd be happy to come over and help if needed. I can't provide much technical knowledge, but if you need an extra pair of hands let me know.
Well, I'm planning on putting the engine back together tomorrow and then maybe mount it in the evening. I know you'll be riding tomorrow morning, but if you feel like dropping by after that, I could use another pair of hands. You got my number, text me and I'll give you my address.
Double check those magnets in your rotor. I can't see them in the pic above, so make sure there is equal space between them while you have the engine accessible.
Today I cleaned both side covers (clutch cover and generator cover). I removed the nasty stuff left by the original gaskets.
And since I didn't want to re-use those ugly original gaskets, I created my own using a thin layer of RTV Gasket Maker (black high-temp silicone).
... and proceeded to install the covers:
... off to bed now.
Tomorrow I'll install the head covers and re-assemble the bike. ;D
Oh, by the way, that Walmart carb cleaner is my best friend for keeping things clean... but if you're going to use it, make sure to keep the work pace well vented or you will experience a sudden rush of unexplainable joy and happiness. arty:
Installing the exhaust system... a major pain, specially the rear one. Those bolts have to come into one of the hardest to reach holes you can imagine.
Thanks to all of you who followed and supported this project :mrgreen:
Now ride!
Sent from my right shoe using the Motorcycle app
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StromTrooper
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Since 2003
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