Topic: Learn from my mistake!

[egar]

After seven months of hard work, I was finally to the point to where I was reassembling the motor. Several hours deep into the reconstruction today, after installing the cam and camshaft, rockers and such, I reach for the bag containing the cam chain tensioner. Also in the bag, I found this:


Which means I have to tear the whole engine apart to put this frigging thing in. yes, I literally had tears in my eyes. Time to quit work in the garage today and drink a cold beer.

[jacquesleclochard]

Sucks, man. I'm really sorry to hear that. Not meant as a hijack, but to show I share your frustration...

After replacing the camchain during a teardown, everything went smooth untill the chain snapped. I removed the engine, opened up the top end and found out that I forgot to properly link the chain by mushrooming the pin in the link.

Two bent exhaust valves, another new camchain, a new top and a bottom gasket, and lots of hours.

[egar]

Thanks for the reply. I was so pissed off that I needed make this post to hear someone else's sob story so that I can remind myself things aren't so bad and that this is actually supposed to be fun...Nobody else understands the frustration.....

[8 Track]

Oh, I could tell you some stories.  Nice thing is, you become very smart after making silly mistakes like this.  Bad thing is, you'll become so smart (dumb as I was) that you'll get a "god complex" like I did.  Ha, a year from now, you'll be laughing about this.

[KRONUS0100]

well...at least your cam gear bolts didn't back out (after fresh rebuild) because you forgot to stake (with a Chisel)  them after torque.  Cost me 4 bent valves and new cam and gear, plus gaskets, labor, etc....oh and trailer and truck to get bike home after it happened.

[jtb]

I left the big O-rings that go under the jugs out 

[Spanner 1]

Sorry for your mistake........ but what a clean motor rebuild your doing.!!  ... looks great.

[manjisann]

It sucks to have to tear back into the engine, and I realize it's small consolation, but at least you found it before putting the engine back in frame and trying to run it. I've got to be honest, I'm not really sure what that part is though??

We share your pain, and understand your frustration 

[Spanner 1]

Why it's the lovely cam chain guide... need to lift the jugs off to get it in place, I think.

[754]

You only need to pull the top end off.. a few hours + gaskets.

 If your base gasket is not stuck on, you may be able to lift cylinders and install it.. BUT DONT LET THE PIN FALL IN..use a rag under it..

[bryanj]

How about rebuilding a 1960 bonnie and turning round to find 2 wristpin circlips on the gatepost,

NOW were they the new ones to go in or the old ones comming out-----DOH.

Couldnt risk the new 750 Morgo kit and they were the new ones

[sangyo soichiro]

After seven months of hard work, I was finally to the point to where I was reassembling the motor. Several hours deep into the reconstruction today, after installing the cam and camshaft, rockers and such, I reach for the bag containing the cam chain tensioner. Also in the bag, I found this:


Which means I have to tear the whole engine apart to put this frigging thing in. yes, I literally had tears in my eyes. Time to quit work in the garage today and drink a cold beer.

I'm sorry, but this gave me a chuckle.  Not laughing at what happened, but just because I can totally imagine something like this happening to me.  Look at the bright side though, at least nothing is ruined.  Easy fix (although time consuming).  Have another cold one.   

[Freaky1]

After seven months of hard work, I was finally to the point to where I was reassembling the motor. Several hours deep into the reconstruction today, after installing the cam and camshaft, rockers and such, I reach for the bag containing the cam chain tensioner. Also in the bag, I found this:


Which means I have to tear the whole engine apart to put this frigging thing in. yes, I literally had tears in my eyes. Time to quit work in the garage today and drink a cold beer.

I'm sorry, but this gave me a chuckle.  Not laughing at what happened, but just because I can totally imagine something like this happening to me.  Look at the bright side though, at least nothing is ruined.  Easy fix (although time consuming).  Have another cold one.   

No matter how much it sucks, it is always better to find these things out before your blasting down the road.

[754]

 Hope... you didnt by chance put a new one in, and that is the used one in the bag....

[Spanner 1]

OOOOOH, 754 further complicates the issue, haden't thought of that scenario !

[754]

Would be a good thing, pull valvecover & check with a flashlight..

[bikerbart]

All I got to say is thank god I put in a frame kit.I opened my top end twice already.In two weeks.(camchain on the sprocket wrong)

[Rosinante]

How about rebuilding a 1960 bonnie and turning round to find 2 wristpin circlips on the gatepost,

A mechanic friend once told me they would sometimes put a wrist pin clip on somebody's work bench after that person had just rebuilt and installed a motor.  Funny huh?   

[City Boy]

Hi bart.Well at least you found the missing part before starting engine.Way back,after finishing the first engine rebuild I was allowed to do at the shop I was apprenticing at,an S90,I left the drain plug loose.The customer picks it up and loses all his oil within a few blocks!Back he comes.He is only upset that he may have to pay for the new oil he now needs.I am devastated.Fortunately,the little engine seemed no worse off.The boss fixed him up and sent him on his way.His next words to me I have burned into my brain.Jimmy,not to worry,IF YOU DON'T MAKE MISTAKES YOU AREN'T DOING ANYTHING!    Rock On

[Skonnie Boy]

Yeah, on the bright side, the engine is still not in the frame.  Imagine if you'd hoisted it back in the frame and had to remove it again.  That was the fear that kept me awake at nights when I last rebuilt my engine. 

I've rebuilt my kz650 twice and it STILL doesn't run.  I'm only recently able to laugh about this.

[Stev-o]

After reading some of these horror stories, you shoudn't feel as bad!
Have another cold one...

[Hush]

It's always a horror to have rebuilt part of your motor and have bits left over.
I couldn't even remember what the heck the strange wee dome shaped object was nor which bike it came off until my 650's clutch failed to work.....thrust washer, that's what that thing is eh!

[KB02]

I was just about to the point you were at (not quite) when I dropped the cam chain down into the engine, and not matter what I tried, I couldn't get it back out. Had to tear down the whole top end. Broke a ring on the second install of the jugs.    I know where you are at, my friend. You are not alone. 

[phrige]

I've rebuilt my kz650 twice and it STILL doesn't run.  I'm only recently able to laugh about this.

 Chuckled so hard at this one, Oh man Skonnie Boy I feel your pain. Not through engine rebuild per-say but there have been countless life situations where i feel the same.


 I love the persistence you guys have. I know when I crack into my engine rebuild, I'll know exactly why

oh and Rosinante you had me rolling with the wrist pin gag too. Now thats a real classy move!

[egar]

Got the engine torn back down and now I can't get the valve head apart from the cylinder head because the new head gasket's stickiness is holding them together. When I pull upwards, the whole thing starts to lift off the crank case. I called my mechanic and he's convinced I forgot to remove a head bolt somewhere but I know this engine by heart now. I'm trying to find a way to split the two pieces without bending fins or screwing up the head gasket.

Suggestions?