Multi-problemed bike (electrical + ???) - Page 17

Water Warrior 2 · 04-03-2014, 01:45 AM

Quote:

Originally Posted by raul10141964

impact driver is the correct tool

That is the perfect tool for tight bike hardware. Cheap and built to last a lifetime. Mine is over 35 years old and still looks new. Haven't needed it often but sure glad to have it in the tool box.

ImaginativeFig · 04-04-2014, 11:27 AM

I'm pretty sure I just cracked the replacement cover too.
This time I played it (what I thought was) really safe. I first tightened down the two bolts with bushings, not super tight, but to the point where there was some resistance and the cover was touching the bike at those points.
Then I finger tightened the rest of the bolts and took out an in-lb torque wrench. I started at 25 in-lb (2.82 Nm) and tightened all the bolts to that. There are 8 bolts so I'd start at the top, then move 3 over, tighten that, move 3 over, etc, 'til I returned to top, if top was no longer tightened to 25 in-lb, then I'd do them all again in the same pattern. If it was still at 25 in-lb, then I upped it to 30 in-lb repeated tightening procedure, up to 40 in-lb, repeated, then up by 10 in lb at a time all the way up to 120 in-lb at which point it cracked. Same place as before. Booooooooo

So yeah, apparently the limit for the magneto cover is just under 10 ft lb (13.56 Nm)

raul10141964 · 04-04-2014, 12:12 PM

Torque chart from the service manual

alantf · 04-04-2014, 12:17 PM

You must be a mind reader

I've just downloaded it, and when I've come to post it, I've found you've already done it.

mainlinecoffee · 04-04-2014, 11:07 PM

What size are the side cover bolts? Maybe I'm a moron but I just crank em til they squeak than bring on the loctite

Water Warrior 2 · 04-05-2014, 12:04 AM

Quote:

Originally Posted by mainlinecoffee

What size are the side cover bolts? Maybe I'm a moron but I just crank em til they squeak than bring on the loctite

Be careful with the squeak theory. That may work with cast iron but aluminum is close to stripping out the threads with a squeak. Put blue Loktite on the threads of the bolt and run them in snug.

mainlinecoffee · 04-06-2014, 02:09 PM

Yeah I learned that the hard way working on a Lifan dirt bike. The stator plates are awful to pound in too

ImaginativeFig · 04-07-2014, 11:04 AM

Quote:

Originally Posted by raul10141964

Torque chart from the service manual

Ah, wow, so I was way overtightening (which I suppose was obvious anyway)
I think I really need a printed version of the manual, I keep missing things searching through the digital one.
In the engine reassembly instructions I believe it says something asinine like "tighten the cover bolts securely" which is pretty damned objective. Woulda been nice if they just constantly threw in reference to that table.

raul10141964 · 04-07-2014, 02:43 PM

on page 7-24 is the torque specific for the chassis

ImaginativeFig · 04-20-2014, 04:26 PM

Tried putting on the 2nd replacement cover today, measured the bolt diameters at 7/32nd with a crappy caliper, which is 5.5 mm, so I rounded down for safety and liklihood to 5mm, which the table on 7-25 says should be torqued to 2 lb ft, onlything is that at 2 lbft, the cover isn't even pulled flush with the body of the bike, so I turned it to 3 lbft. Still gap. 4 lbft. POP! No visible crack, but it's probably there somewhere. We can still get a piece of paper in between the parts on the troublesome left side.
I'm not really sure what to do at this point. Assuming the crankcase must be warped somehow. Or I'm somehow doing something very stupid.

04-04-2014, 11:27 AM	#162
ImaginativeFig Senior Member Join Date: Jan 2014 Location: College Station, Texas Posts: 138	I'm pretty sure I just cracked the replacement cover too. This time I played it (what I thought was) really safe. I first tightened down the two bolts with bushings, not super tight, but to the point where there was some resistance and the cover was touching the bike at those points. Then I finger tightened the rest of the bolts and took out an in-lb torque wrench. I started at 25 in-lb (2.82 Nm) and tightened all the bolts to that. There are 8 bolts so I'd start at the top, then move 3 over, tighten that, move 3 over, etc, 'til I returned to top, if top was no longer tightened to 25 in-lb, then I'd do them all again in the same pattern. If it was still at 25 in-lb, then I upped it to 30 in-lb repeated tightening procedure, up to 40 in-lb, repeated, then up by 10 in lb at a time all the way up to 120 in-lb at which point it cracked. Same place as before. Booooooooo So yeah, apparently the limit for the magneto cover is just under 10 ft lb (13.56 Nm) Last edited by ImaginativeFig; 04-04-2014 at 11:32 AM.
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04-04-2014, 12:17 PM	#164
alantf Senior Member Join Date: Nov 2008 Location: Tenerife (Spain) Posts: 3,719	You must be a mind reader I've just downloaded it, and when I've come to post it, I've found you've already done it. __________________ By birth an Englishman, by the grace of God a Yorkshireman.
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04-04-2014, 11:07 PM	#165
mainlinecoffee Senior Member Join Date: Oct 2013 Location: lexington ky Posts: 223	What size are the side cover bolts? Maybe I'm a moron but I just crank em til they squeak than bring on the loctite Login or Register to Remove Ads
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04-06-2014, 02:09 PM	#167
mainlinecoffee Senior Member Join Date: Oct 2013 Location: lexington ky Posts: 223	Yeah I learned that the hard way working on a Lifan dirt bike. The stator plates are awful to pound in too
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04-07-2014, 02:43 PM	#169
raul10141964 Senior Member Join Date: Apr 2012 Location: Elkhart, Indiana Posts: 369	on page 7-24 is the torque specific for the chassis
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04-20-2014, 04:26 PM	#170
ImaginativeFig Senior Member Join Date: Jan 2014 Location: College Station, Texas Posts: 138	Tried putting on the 2nd replacement cover today, measured the bolt diameters at 7/32nd with a crappy caliper, which is 5.5 mm, so I rounded down for safety and liklihood to 5mm, which the table on 7-25 says should be torqued to 2 lb ft, onlything is that at 2 lbft, the cover isn't even pulled flush with the body of the bike, so I turned it to 3 lbft. Still gap. 4 lbft. POP! No visible crack, but it's probably there somewhere. We can still get a piece of paper in between the parts on the troublesome left side. I'm not really sure what to do at this point. Assuming the crankcase must be warped somehow. Or I'm somehow doing something very stupid.
	0