z1100st A1 (re - birth) lots of pics?

Hinckley · #76 PostAuthor: **Hinckley** » Mon Mar 09, 2015 1:56 pm

One step beyond - Madness - Not at all. On my first day as an apprentice I found out you have to 'DO' to 'LEARN'.

And you CAN do it - it's a heap more basic than you think.
Take loads of pics - make notes each time you take something apart - which way round things go and in what order - note spring tension and direction - how things like cables or wiring is routed - it helps with learning which bit goes when and in what order and which way it faces when it's time to re-assemble.
Take note of the bolts as you remove them - they will be of differing lengths and diameters - some may have threadlock on - I draw a pic on some cardboard and make holes to take the bolts as I remove them, I mark the cardboard if they are loctited or have a washer etc.
Keeping assemblies like gears together - stuff like that.
If you wake up in the night with a sudden realization you missed out the bearing or didn't torque up this bolt or that bolt - write it down and check later.
Thread check everything, lubricate every thread, torque every bolt.

In a perfect world doing a video would be best - but it's hard to hold the camera at the same time as spannering - plus it gets covered in oil and it catches all the swearing......

If you get stuck - do a search - or ask - I have found the combined knowledge on the forum to be truly amazing.

It may be frowned upon for obvious flammable reasons - but petrol works very well to get most of the surface gunge off, most of the cleaners available to us now are so namby pamby you could almost clean your teeth with them.

Following with interest - Good luck

#77 PostAuthor: **Ginger Bear** » Mon Mar 09, 2015 6:35 pm

Freddy,

Splitting the cases is not as difficult as you think.

My advise would be to find some large clean containers & put everything that comes out of the cases into the containers. The gears clusters, clutch etc will come out as complete items, there's no need to strip them any further.
When you reassemble, you'll know it's all back in when your containers are empty.

A manual is useful for reassembly as some of the crank bolts require sealant, also watch for the crank locating pins. They can easily be overlooked & pushed into the cases when the whole thing gets put back together. :??

freddyz1r · #78 PostAuthor: **freddyz1r** » Tue Mar 10, 2015 10:06 pm

Well chaps, I've all but done it :shock:

took me about 2 1/2 hours to get to this stage. I'll post the full story/photos tomorrow (it's bed time :oops:

)

got to get the 'selector forks' out yet, I'll have to have a proper look how they come out.
cheerz freddy

freddyz1r · #79 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 10:37 am

Well the pictures have been slow coming, as I have encountered several problems with the 'samsung galaxy tablet','photobucket' and 'gallery'. I have lost several pics :oops:

( I've looked down the back of the sofa :??

, they are not there :shock:

), or pics have 'semi-blanked', as shown here:-

I have been informed (by 'technical support' :roll:

,((also known has a stroppy teenage son :lol:

)) that the 'sd card' is the issue :dead

) that most of the 'missing' photos can be retrieved at a later date :cry:

, when he who is of an higher intelligence can be bothered :evil:

So until then, you'll have to make do with a few 'missing' parts to the 'photo storyline'
Cheerz freddy

freddyz1r · #80 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 6:55 pm

Getting this thread up to date, (you'll have to fill in the blanks yourself :lol:

)
Started off measuring, (didn't realise there were 3 different heights 'till now :oops:

)

they were a right swine to undo :hot

is that an 'oil way'? Do I have to remove it?

freddyz1r · #81 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 7:11 pm

Are the nuts still available :?:

these are quite rusty

half way there, took me over 40 minutes with a plumbers wrench to remove all 12.They were definitely lock tighted in.

using hinkleys good advice, marked up a block of polystyrene (not cardboard :oops:

) and wrote all the heights in mm. Good storage for these rods.

freddyz1r · #82 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 7:17 pm

Took note where the 'o' rings are situated.

and where the wiring thingys belong :roll:

freddyz1r · #83 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 7:22 pm

These 2 bolts came out with a bit of a bang :shock:

and a couple of puffs of what I presume was dried up old locktite :??

freddyz1r · #84 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 7:27 pm

Another wiring thingy hiding from under the starter area

freddyz1r · #85 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 7:48 pm

Removed 8 of the 12 crank bolts. 4 from the left, 4 from the right.

then realised that the crank cases had 1-8 cast into them :oops:

Thought I better match and number the different length bolts :wink:

freddyz1r · #86 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 8:03 pm

Tried levering the cases apart :??

Mmmmmm, better take these out first :oops:

Separate this off.

errrr, I don't know how I missed it :ws

freddyz1r · #87 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 8:07 pm

Quite a selection of bolts their

freddyz1r · #88 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 8:15 pm

Thought I'd try and split the casings again :lol:

while trying to lever the cases apart, I found the 'original bakerlite' :shock:

we'll come back to that later :wink:

freddyz1r · #89 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 8:22 pm

hooray, we're in :up

first big bits in the box (ala GB's idea)

freddyz1r · #90 PostAuthor: **freddyz1r** » Fri Mar 13, 2015 8:27 pm

Now the 4 inner crank bolts

found another 'o' ring ( probably wasn't lost)

z1100st A1 (re - birth) lots of pics?

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