Reassembly Woes: Stuck pistons

[ameen]

nice, good thing i came across that. Damn, that gets me to thinking, i hope there are not any other small pieces that lost...

First time building an engine is always an adventure.

[mike_of_bbg]

Yeah, I lost that piece myself and the spring that goes with it. They were about $1 each from my local Zook dealer. They kept using the same plunger up until 2004 or 2005 on some bikes IIRC. Loss of the gear indicator is not such a big deal to me, but it's really nice knowing when I'm in neutral

There shouldn't be too many surprises like that.

[ameen]

Update: so i got the pistons in. Noticed something new though. The nubs on the end of the crankshaft are broken


can i just JB Weld them? I am not about to replace the crankshaft.

[ameen]

so, i guess the pic the didnt upload.
but what is my best option? it is the nubbs under the 19mm bolt on the right side of teh engine that turns the crank.

[67fire]

Are you talking about the lobe that the points ride on?
What "nubbs?"

Eric

[ameen]

these ones

[67fire]

How are they "broken?" Those are the pick-up points for your electronic ignition.

Eric

[ameen]

i took the bolt off already and there are two sheared off spots where there used to be the nubs. they point in the direction of the crankshaft.

[67fire]

I don't have factory elec. ignition so I don't know what is missing. Perhaps some kind of insulator? Someone will chime in and explain it to both of us, I hope. I would think that whatever it is, it is replaceable.

Eric

[rapidray]

He is referring to the END of the mechanical advancer where it has 2 outward "pins" that locate the outer nut on the end of the crank that holds the mechanical advancer on. All you need to do is get another mechanical advancer! You crank is fine! I have attached a picture. Ray.

[rapidray]

Sorry, you can't add a pic in the "edit" mode. Ray.

[rapidray]

Here it is with the big nut covering it. Ray.

[67fire]

Thanks for posting the pic Ray! I knew that it could not be THAT bad...

Eric

[ameen]

thank god. Anyone know where i could get one?

Thanks

[Suzuki_Don]

Yes RAY has one.