Sungjin Lee What did I do

First I removed the two exhaust pipes because they was bad to keep using which why it was going to cut on end of the part so it will be replace to new(only other side)

but my area is brake and I removed cap of back wheel for cheeking the blake which cause the blake part behind on the wheel of cap so I removed that first and then I removed the brake caliper and I carried brake caliper to table and I checked still working and I disassemble the brake caliper for looking at piston, brake pads and rubber cap I could found the problem that problem was the brake caliper piston has a lot of dust so I trying to clear the  dust by sandpaper but that had a damage so the pistons will be replace and I also cleared hose with pressure brake fluid,  

and brake pads wasn’t useful because they was too old so they will be replace too and the rubber cap also had a dust but it will using again and of course I will cleaning that parts

,so here is I need to do conclusively first I need to get new part(brake pads and brake caliper piston) and second I will do assemble again successfully.

Specific Blog Post Assignment - Yamaha XS 650

This blog post will focus on the electrical system of the bike and its components. Eric and Steffen are looking into the engine and its components, while Alec and Sunjin are focusing on the brakes and suspension.

The following is a list of all the tasks that I have accomplished so far on the bike.

• Disconnected and labeled wiring inside headlight casing
• Removed front fork and wheel
• Removed handlebars and speedometer
• Disconnected wires connecting to battery casing and other components on the outside
• Removed rear suspension and rear wheel
• Removed battery casing
• Removed all electrical wiring
• Sanded, cleaned and sprayed connections to help prevent corrosion

The next steps for the electrical system is to finish cleaning the connections, replace a couple components and then reattach everything once it is cleaned.

Three components in the electrical system include the battery, ignition coils and the electrical connections.
The old battery on the bike is to far gone to service. We will have to order in a new battery for the model of the bike. The terminal connecters will also need a cleaning.
The ignition coils are in good shape but, doing a little research, we found out that stock ignition coils on these bikes have a very weak charge. We will most likely be replacing them with an upgraded version that provides a stronger electrical charge.
The electrical connections are somewhat dirty and corroded. I was able to clean some of the connections, but they all need to have a good cleaning. Before being reconnected, all the connections need to be sanded and sprayed with an anti-corrostion material.

Blog Assignment

Steffan and I have been working on the engine of the bike for quite a while now and it has been going swimmingly. We started by taking the engine off the frame and ended with a bunch of pieces all over our working counter that needed to be cleaned and prepped for rebuild. Here is a list of the work I have done to get to this point.

List:

• The first task was to take the engine off of the frame removing key parts attached to the frame.
• I took off the speedometer reader, kick starter and air filters.
• Once done we had enough stuff detached and then Moved the engine to our working area and started planning on how we can remove things.
  
• The first thing I removed was the carburetor. It looked good and we didn't have to think about buying a new one or cleaning it.
• I then took off the valve cover which exposed the cylinder head.
• I thought the Cylinder head looked a little musty so we decided it should get cleaned
• I then took off the appropriate bolts to take off the cylinder head and was able to get a clean view of the cylinder.
• I saw the cylinder and saw the ceasing right away.
  
• It didn't take us long to hammer the piston out and get the cylinder off the engine.
• I knew we had to clean the cylinder and get it ready to be used again.
• Lucky the piston can be used again but the rings were worn out and useless.
• After the engine was taken apart I started to clean a lot of components such as the carburetor pistons, and valve cover so they would be ready for the next installation.

Part 2:

1. 1 part of the bike I am working on is the cleaning of the bike which I think is very key because it could make the engine work at the end of the day, also it looks very nice. The cleaning of the piston is the most important so that it has a smooth ride and there is no problems.

2. Another important part I am working on is the piston rings and making sure they all go together properly. If this is not put together properly then it could result in engine failure or stuttering of the engine. We must make sure no cuts or bends in the rings.

3. The most important part of the whole operation is to make sure the cylinder is deglazed and really clean. This was the problem of the engine in the first place and we need to make sure its all clean and ready for installation and a nice start up.

Job-specific blog Post

Assignment

Part 1:

The first thing that I did to the Yamaha SX 650 was remove the engine from the bike frame. This was done by removing the drive chain which attached the drive gear inside the engine to the rear wheel. Next we removed bolts securing the engine to the frame alone with removing the electrical components. Because the bike is a kick start there wasn’t as many electrical components it was mainly the ignition advance. Once the engine was removed from the frame I removed the carburetors from the engine. Because the bike sat for so long outside the carburetors will have to be cleaned. I then began to remove the top end oil tube, valve cover and cylinder head. We did this because when we used the kick starter to try to start the bike it wouldn’t move leading us to the assumption that one or both of the cylinders were seized. The cylinder head was removed by taking the bolts off, the ignition advance and removed the cam shaft and chain. We did not have a chain breaker to remove the chain but we used the cam chain tensioner to release as much slack as we could so we would be able to slide the camshaft out of the engine. Once we got the piston free we sent the cylinder and cylinder head to a machine shop where they performed a process called Deglazing. This process was basically a big oven that burnt all the years of rust and grime off the components. I then spent time cleaning the grooves where the piston rings had been because the seized piston had resulted in seized piston rings and lots of built up grime. I then took the side covers off to inspect the rest of the engine. It was apparent that the previous owner had taken very good care of the bike because the inside of the engine was very clean as a result of regular oil changes. Upon further inspection of the oil filters we noticed that there was an abundance of black flakes of plastic and metal. This was a result of the cam chain guide needing to be replaced.  

Here you can see the removal of the seized piston and cylinder.

Part 2:

1: The seized piston was a major concern. It took a lot of sanding and cleaning to get it back to the way it should be. Wellst trying to remove the stuck piston rings we made some imperfection is the cylinder making us wonder if this would affect the performance during the compression, luckily the machinist said that the new piston rings should make up for those small imperfections.        

Here you can see the piston ring gaps being chiseled out.

2: The cylinder block was another major concern. The carefully machined walls of the cylinder were coated with grime and rust begging the question of how to clean and repair them without damaging them. After some research we found that the local machine shop can perform a process called “Deglazing”. The Deglazing process is basically a big oven that bakes the grime and rust at such a high temperature that it falls off leaving the perfectly machined surface.

3: Since the bike has sat for so many years exposed to the elements it is safe to assume that the carburetors are filthy. We will have to look into whether or not the disassembly is something we can do at school or something we will have to pay someone to do. Either way the two carburetors are a crucial part of the engine and will need to be cleaned and rebuilt.

Tech assignment Alec Dawdy

What I have done so far on the motorcycle.

-Removed seat

-I took it off for when I was going to power wash the bike because I didn't want to get the seat wet

-I took it off by flipping the seat up and taking the screws off from underneath it then I was able to remove the seat

-Power washed the bike

-We power washed the bike to wash the bike off because it was kind of dusty and had some dirt on it

-Took off gas tank to sand it        

-Sanded gas tank to prep for painting with 320 grit sandpaper. We did this to make the tank smooth and nice to paint.

-Shocks

-To remove the front shocks, I had to first remove the headlight, the speedometer and the handle bars

-Once I got the shocks removed from the frame I disassembled the shocks.

-I had a problem where I had to make my own tool and prepared the outer part to be polished

-Removed the headlight

-I took the headlight off so Ben could look at the wiring in it

-Removed the handle bars

-I had to remove the brake lines and some bolts to remove the handle bars. I removed the hand bars so I could take the shocks off and so I could later on polishes the hand bars.

-back shocks

-I took the back shocks off to clean them up and then take the back wheel off

-Taking the back wheel off

-I took the back wheel off by taking the nut off the bolt that was holding the wheel to the frame and then lightly tapping the bolt through with a hammer.

- Got a new seat because the old one was rusted and really dirty. We even found a wasps’ nest and some cocoons

-We used some of the parts from the old seat such as the the latch because the one on the other seat was damaged.  

-And now the class (the boys) has fully disassembled the bike.

A scattering of parts!

Good work boys!  We've reached a milestone in the process, where all components have been removed and are in process of inspection, cleaning and repair or replacement as necessary.  The picture shows most of the parts that were removed.  Seems so simple when it's all in pieces!

This week will focus on a summary assignment and further research and preparation of components for re-assembly.  Stay tuned!

Yamaha XS650 - October 23

Today we didn't do much in the shop. We have gotten to a point in the restoration where we must research the next steps. As of today, everything has been removed from the frame of the bike.

The valve cover, cylinders and pistons have all been removed and cleaned. Steffen removed the seized piston rings and cleaned in there as well. Now, they need to resemble the engine.

The electrical wiring has all been removed and now needs to be sanded and cleaned. I began cleaning the connections today and sprayed them with a protective film to remove the corrosion.

today we work really hard

firstly seffien finished cleaning the engine and then dried it off with the air line

             

                                                                                    

and Eric was cleaning the gasket material off the engine covers


 me and sangen removed the back wheel

ben removed the box witch held the battery
the boys had a very productive day.

Cleaning day

Today the Boyz and I got a lot of work done. Alec got a lot of work done today. He made his own custom tool to take apart the front shock. He also removed the rear shock getting ready to clean it and fix it up. Steffan and I cleaned a lot today. We cleaned all the pistons, the whole out side of the engine, and the side covers of the engine. Ben took apart a lot of electrical today and it ready to clean those and get them ready for reassembly. Overall it was a good day and the Boyz got a lot of work done.

Yamaha xs650 - October 17

Things are moving along quite well with the bike.

Today, Alec began servicing the front shocks. He drained the oil and removed both springs from the casings. He is continuing to dismantle the shocks further.

Steffen and Eric continued to work with the pistons and piston rings. Today, they began cleaning and polishing the pistons. Eric also took some time to look up the new piston rings we are going to order.

Sunjin and I continued to take disconnect and label wires toward the rear of the bike. We are also trying to remove the battery casing to remove the rust. We suspect we might need to remove the back wheel to take the battery casing out. We removed the tail lights and guard on the back tire.

 to day the boys did allot of things

firstly Ben took apart the wiring in the head lights and labelled all the wires then he was able to fully take off the handle bars

 then Alec took the shocks off the front wheel and label the left and right shocks

 Steffan and Eric tried to get the seized piston rings of the seized piston is difficult then expected quote "its not what ya want"

Today The Boy's  had one of the most productive with a lot big achievements. Eric and Steffan removed the cylinder head, removed the pistons from the cylinder.

Alec and Ben removed the front end and fork so they can continue to repair / rebuild the front fork.   

What we Did on the Bike today - October 14th

The Boyz and I got some serious work done today. Alec took off the head light, Ben disconnected some of the wires inside of the headlight casing to take the handle bars off. Steffen and I took of the necessary parts like the advanced started unit to remove  valve cover. Today was very productive and we will be able to move ahead of our work a lot better now because the valve cover is removed.

first off today the boys went in and did work

Stefen and Eric removed the two carburettors.

then they heated the nut for the oil line with the torch to remove the oil line

and Alec began to dissembled the head light