Vehicles

650 - getting it running part 1: engine teardown

So regardless of any other problems related to the ignition, brakes, etc. the primary problem was that I could not get the engine to turn over. The starter couldnt do it. I could put all my weight on the kick starter and it would not budge. Even with both spark plugs out, it would not turn over.

I removed the engine from the bike and started tearing it down, hoping to find something obvious like a broken gear or misplaced bolt. No such luck. I found absolutely nothing wrong with the engine as I dismantled it. Bummer.

In my mind I partially resigned myself to the fact that the 650 may never run again. I put that thought to the side and started reassembling everything. This time, I tested each component as best I could as I reassembled the engine.

In the process of doing this I did notice that the gear selector, while it did select all gears, would sometimes get stuck in between gears. This lead me to part 2: gear selector.

Pictures

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Boyer unit, just about to be removed
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donor engine came with a new stator and new (non melted) pickup coils
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it does not matter how much oil you drain out, there is always more and its always in a puddle
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donor motor crank, original tranny, all look good
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