Discoveries during a rebuild - Travis
As you know I rebuilt my 99 deluxe as a "must do" rather than a "would like". So I pulled the whole motor apart to make a 535. This is what I discovered on mine. But bear in mind no two are even remotely the same.
I replaced the following due to wear not because it self destructed after 40,000 kms.
Valve seats (probably cause I ran 95 octane on OEM seats)
Valve stem caps (damaged and worn)
Decarbonized the head
Renewed stretched head studs and bolts
Oil pump sprindle (worn gearing)
Oil pump worm (worn gearing)
Piston (mine came apart but had noteable blowby at each side of the gudgon pin, probably caused buy the lower compression ring seizing)
Rod was in excellent condition as was the connecting rod bush (but I replaced it with a new forged one with roller)
Crank case bearings both sides due to slight wear nothing outrageous though (replaced them with japanese ones for piece of mind.)
Oil seals associated with those (why because it was cheap!)
New chain
New rear hub/sproket (had wear due to a nuts chain and had teeth missing.)
Emptied and flushed front fork oil (it was weeping but was amazed at the crap that came out with the old fork oil when flushed)
My regulator/rectifier was playing up toasting my battery. Was throwing in a full 17 volts into the battery causinn it to drop cells.
All the other stuff apart from the hi cap oil pumps was cosmetic.
I replaced the following due to wear not because it self destructed after 40,000 kms.
Valve seats (probably cause I ran 95 octane on OEM seats)
Valve stem caps (damaged and worn)
Decarbonized the head
Renewed stretched head studs and bolts
Oil pump sprindle (worn gearing)
Oil pump worm (worn gearing)
Piston (mine came apart but had noteable blowby at each side of the gudgon pin, probably caused buy the lower compression ring seizing)
Rod was in excellent condition as was the connecting rod bush (but I replaced it with a new forged one with roller)
Crank case bearings both sides due to slight wear nothing outrageous though (replaced them with japanese ones for piece of mind.)
Oil seals associated with those (why because it was cheap!)
New chain
New rear hub/sproket (had wear due to a nuts chain and had teeth missing.)
Emptied and flushed front fork oil (it was weeping but was amazed at the crap that came out with the old fork oil when flushed)
My regulator/rectifier was playing up toasting my battery. Was throwing in a full 17 volts into the battery causinn it to drop cells.
All the other stuff apart from the hi cap oil pumps was cosmetic.
