We'll, I'm at it again...funny how a stint of cold weather and boredom gets the gears turning and the bike into a bunch of pieces
This is my second go at tearing the bike apart, the first being last summer when I first bought it from a friend. At that time, it wasn't cared for and looked like crud. Overheated and it didn't feel as powerful as what I remember a 636 feeling like. I had been wanting a project bike for quite some time, and given the challenge, thought this be the perfect one. My initial intentions were to get it running healthy, and add some flavor since I really couldn't stand the original white/silver color scheme. For those who want to catch up, I have the link below to the original thread I posted just after I first finished v.1 and headed out on the maiden voyage to MotoGP Indy. TheSloMoShow's Build v.1
Round 2 is my desire to increase the aesthetic appeal, run some tests to validate the engine's working order and finetune the ergo's since last summer I really couldn't make it much longer than an hour or two without needing an extensive break. Unfortunately, this second round has taken much longer due to an unexpected snowboarding accident resulting in a broken collarbone (and thus a month and a half away from the bike
). But I'm nearly at the finish line.
I envision a Round 3, where I can tear the engine apart and rebuild with performance in mind but this I don't want to do to the engine I currently have as I may not finish before riding time and spring hits. Thus, I'll most likely try and pickup a spare engine to work on and tear apart in the interim instead. But these are just plans, no need to take action on this just yet...
To gauge the amount of work I have to do this time around, and know what I'm getting myself into I wanted to run some tests first. Mostly for peace of mind, but also to see how an engine such as this can hold up after 30k miles. So first up is the compression test. All were within 7 psi of each other and within spec. No immediate danger.
Since I just adjusted the valves last summer I figure that a leakdown test would prove my good work unless of course the head gasket is starting to go. Surprisingly enough, all 4 cylinders were around 4% leakage give or take 1-2% due to gauge inaccuracies. Thankfully, given the success of both of these tests I knew I had a much easier route to go (versus possibly tearing the engine apart after all because compression etc was out of whack).
Since the leakdown test required draining the oil, I also emptied the coolant and bled the brakes. With the bike empty, I started to work on removing the covers since 1.) I have a new clutch to put in and 2.) I wanted to repaint the covers black to match the frame. Clutch & timing cover gone. Clutch fibers removed. Stator and water pump cover removed.
With all the covers gone, I laid down the initial layer of engine enamel but if you are familiar with my first v.1 build thread you know the issues I have run into with paint. For whatever reason, these first few layers on engine enamel had wrinkled up on me (quite possibly there was acrylic laid down at some point that I didn't know about, and the lacquer I laid down after caused it to wrinkle?) Either way, I wasn't going to waste my time trying to fix the issue so I let it dry overnight and started anew the next morning. Covers sanded down, and primed and then painted once again.
Thank the Lord they finally turned out like I wanted (my patience run thinner and thinner everytime I go to paint something lol). Newly painted stator cover and water pump cover. EBC SRC Clutch pack installed just before covers were put back on. Newly painted timing cover and clutch cover.
The previous owner had neglected to take care of his chain, and one day while riding on the highway had his chain break and snap forward breaking the front half of the sprocket cover. Thus, a whole bunch of gunk has always built up on the backside of my starter and anywhere within that general vicinity. I don't know why I didn' choose to do this sooner, but I went ahead and bought a new cover off eBay for $15 and painted it in the same manner as the rest of the covers.
I bolted all the covers back on, filled the bike up with fresh fluids and proceeded to the next step. And trust me when I say this, this is by far the most crucial one for my bike since I swear my TB's have been off since I first rebuilt it last summer. I've had a couple issues with the bike stalling as I quickly let off the throttle and come to a stop, and also notice that it's not quite as reactive as what my previous 600 was or even my current R1.
I only got a picture of after the job was done, but long story short my cylinder 3 was barely creating anything similar to a vacuum. It was completely, absent. I eventually got all 4 back to the same level, gave the throttle a few quick snaps to make sure the changes stuck and then shut her back off.
With the TB sync out of the way, I was able to move on to what I had been looking forward to for quite some time. I'm a bit of a heavier rider than what I believe my suspension is set up for (unless everything is set to minimal compression and rebound but that make for a rough rough ride). I wanted to overhaul the forks originally because the previous rider was known to wheelie quite frequently and after 30k miles I really can't imagine the oil and dust seals performing to their OEM expectations anymore. I also decided to upgrade the fork springs and going with a 1.0k/mm set which will help quite a bit more. Front wheel gone, forks ready to be removed. Fork disassembly area.
I gathered some helpful tidbits off a YouTube video from a fellow member who had some good ideas about creating a DIY spring compressor and few other tools. Both forks completely disassembled and drained.
With the housing and leg separated, I was persuaded to paint the caliper mounts as well since these are really the last remaining parts on the bike (besides the block and head obviously) that aren't already black. Plus, they were pretty dinged up and they needed a makeover. I originally plastidipped the mounts, along with the top yoke and clip ons.
It didn't take me long to realize though that the look wasn't what I was going for so I ripped the plastidip off the caliper mounts (left it on the other parts) and quickly went through sanding, and painting the mounts with engine enamel. Looking good...
Let the legs dry overnight, and then gathered myself to finally get the new springs put back in. Of all the stuff I've done to my bike, swapping these springs was a bitch. Honestly, I don't know why but I found this to be the biggest pain in the ass. Of course with practice makes perfect, but exchanging these the first time around certainly taught me some patience. New Race Tech Springs My DIY jig from which I got the idea on YouTube. It works pretty well ,and saves some doll hairs versus buying an actual spring compressor. All assembled and ready to go back on.
With the front wheel off, I decided to take the opportunity to replace the front wheel bearings. I noticed that I was starting to get some resistance, felt the old bearings were at the end of their life. Front forks back on.