Triumph 650 Motorcycle Engine Disassembly & Rebuild

[T140-Oli]

Todd von Lowbrow Customs hat einen 650er Unit Triumph Twin zerlegt und wieder zusammen gebaut - und das ganze in 13 Videos verewigt. Die Videos sind amerikanisch/englisch. Ich mache jetzt für jeden Teil einen Beitrag mit der Inhaltsangabe auf. Im YT-Video selbst sind auch direkt die Sprungmarken verlinkt.

Bitte beachtet Phils weise Worte viewtopic.php?f=64&t=13996

Part 1: https://www.youtube.com/watch?v=tWCdHG0pz3o

00:34 History of motor and difference between the models.
04:22 how to read the vin numbers and pad changes.
09:47 Installing the Triumph 650 Engine on Lowbrow Customs engine stand
14:43 Beginning of taking the top end apart
15:45 Taking caps off and de-adjust the valves
18:18 Todd discovers the motor is stuck, what to do?
20:58 Taking the rocker boxes off

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Part 2: https://www.youtube.com/watch?v=0hf8pdl722M&t=0s

00:12 Pushrod locations and what to look for if they are bad.
01:59 How to tell if your cylinder head matches your cases.
02:37 How to check your valves for wear or damage.
03:10 Removal of the cylinder head.
05:38 Start to remove cylinder base nuts.
08:39 We took a lunch break and came back to discover something.
09:26 Secure the tappets before removing the cylinder base.
10:20 Break the cylinder base free from the cases and remove.
11:17 Protect your RODS!
12:38 Don't lose your piston clips in the cases!
13:21 Remove tappets, tappet blocks and and inspect.
18:00 Using a tappet block removal tool.
20:25 How to determine if your tappets need replaced.
21:07 How to inspect your pistons and check bore size.
24:40 Removing the pistons from the rods.
27:26 How to determine your pin and rod bushings are good.

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Part 3: https://www.youtube.com/watch?v=ZTm7S5_gYNE&t=0s

00:25 Drain primary and remove primary cover.
03:05 - Removing the stator.
05:15 - Removing nut from the crankshaft.
06:33 - Removing alternator studs and what to look for if worn.
07:30 - Removing the pressure plate.
10:41 - Removing the clutch plates
12:00 - Remove clutch push rod and nut from the main shaft.
14:37 - Remove the rotor.
15:57 - Remove the front sprocket, primary chain, and clutch basket all in one piece.
22:05 - Remove the primary shoe.
26:10 - Remove the cover to gain access to the main drive sprocket, tips and tricks on how to get those pesky small screws out.
29:51 - Spiderwebs!!!
30:43 - Removing the Main drive sprocket.

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Part 4: https://www.youtube.com/watch?v=zgB_xAo4zOA&t=0s

00:16 - Taking off the points cover.
00:40 - Remove the points plate.
02:00 - Remove the advance unit.
02:52 - Cheesehead screws - removing timing cover
06:01 - What's under that timing cover?
06:29 - Remove the oil pump.
07:45 - Removing the three nuts from cam and pinion gears.
08:25 - Remove the nut on the pinion gear.
09:40 - Remove nuts off cam gears.
10:19 - Explanation of the tit on the nut from the intake cam.
11:51 - Remove the intermediate gear.
12:00 - Explanation of the timing marks on each gear and where they go.
12:18 - Remove the gear from the Intake cam.
15:03 - Remove the gear from the Exhaust cam.
17:35 - Remove the pinion gear
20:41 - Remove the Transmission cover
21:08 - F*&$ing Cheesehead Screws!
24:00 - Grab a drain pan and drain the transmission oil.
25:15 - Remove ratcheting gear for kick starter off of the main shaft.
26:26 - Remove the 3 fasteners holding on the inner transmission cover.
28:50 - Remove the main shaft, shift shaft, shift forks, counter shaft, and cam plate selector. Keep gears with each shaft in order.

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Part 5: https://www.youtube.com/watch?v=5OifmNUjfNo&t=0s

00:40 - Start to remove all fasteners holding the two halves together.
05:32 - Remove Tac Drive
08:25 - Plug the Tac drive hole with Lowbrow Customs Plug - https://www.lowbrowcustoms.com/produc...
09:00 - Remove through bolt on front of cases where L bracket attaches for exhaust
10:30 - Check one last time for any remaining oil in the crank case and drain.
10:56 - Remove engine from engine stand if you have one.
11:05 - Remove final two fasteners on bottom of the cases.
12:38 - Important* don't forget to remove the two flathead screws located on the top of the engine by the rods.
15:10 - Double Check all of your work, make sure all fasteners have been removed from the cases.
16:00 - Split the cases using a dead blow hammer.
16:50 - Please don't beat on your crankshaft!
17:24 - Pull the two halves apart, protect your rods.
17:53 - Remove exhaust and intake cams.
18:00 - Crank case breather vent info.
18:25 - Remove timed breather disk from the intake cam hole and explanation on how it works
19:55 - Difference between early and later year's breather systems and what to look for, seals, etc.
21:05 - Remove crankshaft seal if you have one.
21:50 - Later breather system walk through.
22:55 - Remove the crank shaft from the right side case.
24:00 - Again, Do not beat on the crank shaft!
24:20 - Oil Filter Screen overview, removal and cleaning.
28:45 - Remove Transmission Seal.
29:47 - Remove the Snap ring from the bearing on the transmission.
30:04 - Remove your plunger from your transmission or try to...
31:11 - Remove your drain and level plug from transmisson.
31:50 - Try again to remove the plunger from your transmission.
32:16 - Remove the three bearings from the right side case. Crank shaft bearing, transmission bearings - layshaft and main shaft.
37:18 - Check the specs on your cam bushings, they are the least ware item in this engine and most likely will not need replaced in most cases.
37:54 - Wash your crank cases.
38:03 - Gasket scraping tip.
38:30 - Remove the race from the left case. Theres one way to do it and then Todd's way to do it.
39:14 - Chef Todd cooks up some Triumph BBQ

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Part 6: https://www.youtube.com/watch?v=j02o5FTiHwQ&t=0s

00:17 - Remove crankshaft bearing.
03:00 - Removing the rods.
06:45 - Inspect journals and explanation on what to look for with ware on plane bearings and journals.
09:25 - Explanation about the dreaded sludge trap.
10:55 - Sludge Trap Removal.
13:05 - Removing the Sludge Trap plug.
13:41 - Inspect inside Sludge Trap.
14:13 - Remove Sludge Trap Tube
19:40 - Remove the rocker shafts, keepers and caps from the rocker boxes in preparation for vapor blasting.
24:24 - Repeat on second removal of all things on rocker box.
26:30 - Remove all 4 valves from cylinder head.
30:20 - Inspect valves and valve guides fitment as you remove each one. Valve to guide clearance.
31:20 - Bag and Tag each valve, keepers, springs and caps.
37:16 - Dont forget to heat up and remove the lay shaft and main shaft bearings from the inner tranny case.

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Part 7: https://www.youtube.com/watch?v=AJ-K9gT6wRs&t=0s

00:43 - Ken from Ace Powder Coating explains the Vapor Blasting process and why its better then other methods to clean your motor parts.
02:19 - Todd talks a bit more about the benefits of Vapor Blasting
04:11 - Back at Todd's garage. Prep before any installation of bearings and or any new parts.
07:35 - A walk through of what all will be done in this video. What each bearing is and where it goes.
13:04 - Cam bushing check / test.
15:33 - Left side crank shaft bearing install
19:00 - Right side crank shaft bearing install.
24:52 - Install info of the Layshaft and High Gear Bearing.
26:40 - Layshaft bearing install.
29:20 - High Gear bearing install.
33:06 - High Gear bearing seal install.
35:20 - Main shaft bearing install.
37:42 - Layshaft open bearing install.

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Part 8: https://www.youtube.com/watch?v=QGRXM7Yc4q4&t=0s

00:01 - Intro.
00:32 - Installing the sludge trap plug on the flywheel.
03:00 - Punch the sludge trap plug at the seam to secure to flywheel.
03:15 - Clean the journals as clean as they possibly can be.
04:49 - Prepping the rods to go on the journals.
05:23 - Plain bearings overview.
05:53 - Make sure to use assembly lube.
06:40 - Clean the rod thoroughly where the plain bearings go.
06:50 - Orientation of the rod caps and plain bearings.
07:06 - Install plain bearings onto the rod and rod cap.
08:10 - Apply assembly lube to the plain bearings.
08:37 - Install the rod onto the journal of the flywheel.
09:12 - Tighten the rod cap evenly going side to side until both bolts are seated.
09:47 - Torque wrench time. First torque the two rod bolts to 15 foot pounds evenly, then to 28 foot pounds evenly.
11:09 - Repeat steps to do the second rod instillation.
14:35 - Rods install complete.
15:05 - Walk through on how to install left side bearing on to the crankshaft.
16:12 - Install the left side bearing onto the crankshaft.
18:28 - Install the left side case onto the crankshaft.
19:37 - Protect your rods!
20:07 - Put the left side case on a couple blocks of wood so the crankshaft doesn't hit your work bench.
20:31 - Install the cams, use assembly lube on the ends.
22:38 - Put liquid gasket sealer on each side of the crank cases.
24:12 - Introduce the right side case to the left side case.
25:27 - Install your crank case bolts.
28:05 - Cam Check.
31:48 - Fly Wheel Check.
32:11 - Final tighten down your crank case bolts!
32:20 - What's next.... Tootaloo!

[T140-Oli]

Part 9: https://www.youtube.com/watch?v=i5J43phrUpw&t=0s

00:01 - Intro
00:29 - Outline of what will be worked on.
01:41 - A closer look at the Cam gears, and pinion gear and where it all goes.
03:49 - Install tool overview. Don't use a hammer and a socket!
06:05 - Installing the exhaust cam gear procedure.
06:38 - Install key into the key way.
07:40 - Timing dot lined up with your key way.
08:03 - Install your tool on to the exhaust cam, remember left hand threads.
08:27 - Mark a line the tool with a sharpie indicating the center of the keyway.
09:03 - Thread down the other piece of the tool on the gear and tighten the nut, forcing the gear onto the key. Note* Take your time here and check your work if it feels to hard.
12:25 - Repeat steps completed to install on the intake cam gear.
12:27 - Install key in the key way.
14:00 - Install small part of the tool on to the intake cam, remember left hand thread.
14:20 - Mark a line the tool with a sharpie indicating the center of the keyway.
14:26 - Line the gear up to the key way and thread on the other piece of the tool to crank down the nut and force the gear on to the key way.
15:36 - Check your work, make sure after tools are removed that the gears are on the key ways correctly.
16:00 - Pinion gear istall. Put thrust washer on first bevel in.
16:15 - Install key into the key way.
16:45 - Line up dot with keyway on the crank and use a large socket to drive the gear home.
18:00 - Setting the cam timing. Check your work shop manual, based on your model the dashes and dots may be different.
19:00 - Line up the marks on your cam and pinion gears correctly with your intermediate gear based on your work shop manual recommendation.
19:50 - Double check your work
20:13 - Put a dab of red Loctite on your pinion gear nut before installing.
21:06 - Use an old pinion gear to lock gears in place to Torque pinion gear nut to spec. Standard thread
22:26 - Install exhaust and intake cam nuts using same torque spec as pinion gear. Left Hand Thread
23:58 - Install oil pump.
24:20 - Inspect oil pump before installing even if new for any metal or junk that could block the pasages.
24:44 - Line up and install oil pump gasket correctly.
25:15 - Add a small amount lube to the nub where the oil pump rotates on the intake cam.
25:57 - Tighten evenly the nuts that connect the oil pump.
26:45 - Installing the seals in the timing cover.
26:54 - Timing cover seals overview.
28:07 - Using a bearing and or seal driver tool, carefully hammer your two seals.
31:50 - Install patent plate. view separate video here: • DIY Tech Tip: Triumph Timing Cover Pa...
32:27 - Install the pressure relief valve.
32:57 - Prime the crank shaft with oil and why.
35:00 - Install and line up the timing cover gasket correctly.
35:10 - Pop your timing cover on.
35:25 - Put your screws in and tighten evenly. note* the bottom two screws are longer then the rest.
37:53 - Oil pressure sending unit on timing cover overview.
38:40 - Thats all folks! What to look forward to in the next episode.

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Part 10: https://www.youtube.com/watch?v=dNE92wLBnng&t=0s

00:01 - Intro.
00:30 - Cylinder prep and important info.
07:47 - Installation of tappet blocks and Tappets.
17:50 - Check your piston ring end gaps.
24:38 - Install inside clips on pistons.
26:57 - How to install ring on your piston correctly.
29:02 - Installing the pistons on the rods.
32:15 - Installing the cylinder over the pistons.
43:50 - Cylinder head gaskets, Tappet blocks, pushrod tubes, cylinder heads, what's the differences and what to look for.
53:37 - Installing pushrod tubes, cylinder head gasket and cylinder head.
01:02:52 - Rocker boxes! Info about proper installation along with best practices on putting them back together.
01:13:47 - The importance of proper rocker caps and seals.
01:15:03 - Ending and whats up next time.

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Part 11: https://www.youtube.com/watch?v=XTj538XllyI&t=0s

00:01 - Intro.
00:45 - Getting Started.
01:34 - Rebuild the kicker cover.
02:37 - Take Note of the O-ring needs replaced on the shifter shaft
02:57 - Installing the shifter shaft into the kicker cover.
03:35 - Installing springs to shifter shaft.
04:47 - Installing 4 studs with blue loctite for the plate that covers the shifter shaft.
05:54 - Install the plate that covers over the shifter shaft
07:36 - Put a shifter on the shaft to install the selectors with springs.
08:32 - Installing the kicker gear seal.
11:11 - Kicker gear spring location and installation.
12:45 - Installing the selector quadrant.
16:40 - Todd shows how the selector quadrant gear works together with the shifter and the cam plate.
18:43 - What to look for in worn quadrant selectors.
19:16 - Plungers man.. so many different ones and how to install.
20:50 - Install the cam plate and check the action on how it moves with the plunger.
22:00 - Todd shows you where each gear falls on the cam plate slots so you can tell what gear your motor is in.
23:08 - Which gears are what?
23:48 - Installing 4th gear into the bearing of the case.
25:08 - Install main drive gear.
27:25 - How the hell do you torque that main drive gear nut?
29:02 - Different size 4th gears and seals.
30:18 - What worn out gears look like.
31:06 - Installing the transmission oil level plug.
34:00 - What shift fork goes where and how they work.
34:55 - Install one thrust washer using grease under 4th gear.
36:43 - How to index the transmission. The Hughie Hancox method.
38:04 - Installing the countershaft.
38:34 - Installing the countershaft selector fork.
38:50 - Use the shift fork shaft to make sure its aligned correctly.
39:05 - Remove loose gears from main shaft and install on top over countershaft gears.
39:37 - Installing 2nd gear with the shift fork on the groove to introduce to the camp plate.
40:01 - Using the shift fork shaft to align both shifter forks.
40:57 - Install the remaining gear.
41:14 - Install the main shaft through the top gears.
41:53 - Install first gear on the layshaft.
42:40 - Index the transmission by test trial before putting on gaskets.
43:47 - install the inter cover and how to align the selector quadrant to the cam plate.
45:00 - Install the kicker gear to the main shaft.
46:21 - install the 3 screws for the inner cover. Don't crank down.
47:34 - Loosely install the kicker cover to check your indexing.
49:16 - Apply case sealer and install gasket.
49:57 - Repeat process on installation of inner cover and indexing your selector quadrant correctly.
51:27 - Put kicker gear back on.
52:06 - Double check you are shifting correctly before torquing down your kicker gear.
53:13 - How do you torque the kicker gear nut?
54:33 - Bend the lock tab over on the kicker gear.
55:00 - Install the oil fead return line on before putting the kicker cover on.
56:45 - Install kicker gear into the cover.
58:04 - Put case sealer on the inner cover and gasket.
59:32 - Put your kicker and pin on the kicker gear and wind that baby up.
01:00:35 - Install your screws and nuts to your kicker cover and tighten down.
01:02:12 - Put her in neutral and give the kicker a try make sure its returning properly.
01:02:35 - Outro and what to look forward on the next episode.

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Part 12: https://www.youtube.com/watch?v=AwiEHtP0LcI&t=0s

00:01 - Intro
00:25 - What will we be working on?
01:20 - Looking and inspecting the clutch basket.
02:28 - Looking and Inspecting the clutch center.
05:13 - Installing the seal from the crank case to primary if you forgot to do it.
09:17 - Installing the oil seal in the main drive sprocket cover.
12:04 - Putting silicon sealer, gasket, and installing the main drive sprocket cover.
15:56 - Re-install the stator wire tube.
16:24 - Install the primary shoe and adjuster.
19:30 - Prepare the clutch basket, clutch center, clutch, front sprocket and chain to put on primary in one lump sum.
19:55 - Installing loose 20 roller bearings onto the clutch using grease.
22:04 - Place thrust washer over bearings, then clutch basket over top of clutch.
22:39 - Use a new chain!
23:39 - Installing the clutch center. Also a quick explanation on how to change the clutch center rubbers.
26:38 - Installing key on the main shaft.
28:04 - Installing the whole lump sum by sliding on the main shaft and crank shaft.
29:10 - Installing the main shaft washer and nut securing the clutch center/basket.
32:25 - Torque the main shaft nut.
32:50 - Is it ok to have a little wobble in the clutch basket after it has been torqued down?
33:26 - What to look for on a clutch pushrod, what's bad and whats good.
34:57 - Installing the clutch pushrod
35:20 - Installing the Stator studs that go into the case.
38:24 - Install the fat washer to space the rotor and square rotor key that goes on the crankshaft.
40:35 - It's cold in the garage... Installing clutch plates in. What does a worn out one look like?
42:11 - Installing the pressure plate.
46:00 - What does truing your pressure plate mean?
47:37 - Installing rotor and stator
48:50 - Uh Oh... my brand new rotor isn't fitting on the crankshaft!
53:21 - Install the lock tab and center nut to secure the rotor to the crankshaft.
53:56 - Torque the nut and bend the lock tab over.
56:28 - Installing the stator.
01:02:05 - Check clearance of the stator to rotor.
01:05:00 - Till next time WOOOoo!

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Final Part 13: https://www.youtube.com/watch?v=QkPQje6Bm44&t=0s

00:01 - Intro
00:58 - Install your pushrods on the exhaust side.
02:20 - Rotate the engine so the pushrods are at their lowest point.
03:08 - New rocker box gasket!
04:04 - Install rocker box on to the exhaust side, make sure the oil line feed is facing the right side of the bike.
04:46 - Install the two really long top head bolts first. Install two medium length bolts into the rocker box / cylinder head and the three small studs in the front need a washer and nut. Just snug all of them down, do not torque down yet.
08:50 - Rotate the engine to make sure the pushrods are engaged with the rockers.
10:31 - Repeat steps for the intake side rocker box.
18:54 - Torque sequence on how to torque the cylinder head / rocker boxes down correctly and torque specs.
19:45 - Torque 'em dona accordingly.
22:40 - Hand tighten the other nuts and bolts on the rocker boxes.
24:16 - Valve adjustment time! AWE YA
25:58 - Exhaust Valve adjustment first. 0.004 feeler gauge
33:30 - Repeat for intake side on valve adjustment make sure to use 0.002 feeler gauge.
33:57 - Double check your work by rotating the engine over and checking each valve one last time.
34:54 - Install your valve cover caps.
38:14 - Make sure your keepers are tightened down.
39:01 - Installing your clutch cable to the kicker cover. How it all works, what covers do what etc.
42:25 - Adjusting your pressure plate to run true, adjusting the pushrod, and clutch cable on your clutch.
52:12 - Adjust the tension on the primary chain.
54:56 - Reinstall spark plugs
56:18 - Install your rocker feed oil line.
58:09 - That's All folks... it's been real. Thank you again for watching this series we hope you found it useful. Now if you haven't started on your Triumph 650 motor yet! Get in those garages and start digging into it!