Here's the beginning of the engine re-build. There was nothing wrong with it to begin with since it only had 1000 miles on it. But Thumbdoctor wanted the top half of the case for the porting portion of the project, so as long as we're this far, we're going all the way. There will be a different thread for the porting. Keep an eye out for that. I'll let Thumdoctor explain what's going on there.

If anyone has any suggestions as to what to do next, we're all ears. It's not like this is something I do regularly, but I have done it and I'm game to try it again. :thumbsup:

Here it is all laid open.

Here's the top case half, PTO bearing end.

PTO end bearings.

I recommend these guys if you need to replace your crank.
http://www.atelieradrienbernard.com/crankshafts.htm
...cannot beat the prices with a stick; Specially if you use U.S. dollars to buy.

Currency converter...
http://www.xe.com/ucc/

Thanks Joe... I haven't checked the crank yet. I'm hoping that we just need to clean and re-pack the bearings, but you never know. You're right about the prices. They look pretty good. I think I would send my clutches along to be balanced, too.

Im with Idooski, I think clutch balancing seems like a good idea. What can it hurt anyway? Seems to me it can only be a good thing to have everything balanced as well as you can. It may have been good from the factory but who hasnt changed something or everything in there?
Ryan

As this motor is basically a clyinder reed motor,do you think that there are any gains(porting)to be made in the crankcase.Short of finding a way of using the crankcase pressure to pack the ports better Ive always thought that there wasnt much gains to be had.What is your opinion on this topic or what have you been told?We have worked on a couple that had the Emery clyinder port job and they seem to work real well,just wondering if there might be some more on the table so to speak.

Originally posted by Dynamo^Joe@Jul 15 2003, 12:32 AM
I recommend these guys if you need to replace your crank.
http://www.atelieradrienbernard.com/crankshafts.htm
...cannot beat the prices with a stick; Specially if you use U.S. dollars to buy.

Currency converter...
http://www.xe.com/ucc/
:withstupid:

I got my 583 crank from them. Really nice people to deal with!!! Couldnt beat the price. It was cheaper for me to buy a rebuilt crank from them than to repair mine!! That exchange rate helped!!

John...We're really not doing anything to change the port timing. All we're doing is blueprinting the ports and flowing the whole system. I guess we'll wait and see what happens as far as increases realized. But, if you want to know the truth, I'm all goosebumps with anticipation already. :p Just one look at the castings tells me there's a lot of room for improvement. The porting is going to be followed every step of the way in another thread. Stay tuned!

Okay...I've had the top half of the case back from Thumbdoctor for a few weeks now. I guess it's time to get to work. He's still working on the jugs, so I should be done just in time to put them on when he gets here.

I indicated the crank by putting the 2 end bearings in V-blocks. I found only .0001" TIR on the mag end and .0003" on the PTO end. I'd call that very good.

The bearings felt good, so we decided to just clean it up and re-grease it and put it back in. No crank work required.

There was a problem with the water pump rotating seal. It had a piece of aluminum between it and the pump shaft. I elected to replace it. I'll get it started with pics in the next post.

So whats the deal is the BEAST running yet ?