Author Topic: Pilot Engine rebuild  (Read 9832 times)

ludedude

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Pilot Engine rebuild
« on: January 27, 2004, 08:26:36 PM »
Well I started my rebuild...I'll be posting pictures in the Photo Gallery as I get time. Will make a rebuild page up to...like there isn't any out there :lol: Just want to do my own :wink:

Also have a clip of one of the crank bearings dropping INTO the case...yup drop....amazing what winter cold and oven hot can do! :roll: :shock: :shock:

http://www.45thparallel.net/coppermine_dir/index.php?cat=4

PilotSniper

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Great Pics!!!
« Reply #1 on: January 28, 2004, 06:23:38 AM »
Ludedude, great pics! Keep 'em coming!!!
I started out with nothing and I still have most of it left!  :shock:

ludedude

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Pilot Engine rebuild
« Reply #2 on: January 28, 2004, 10:56:13 AM »
Here's the clip of the bearing being dropped in

http://www.45thparallel.net/videos/index.php?subtrack=Pilot&sub=Rebuild

Click ahead one video, then click play, wait for it to LOAD (time depends on your connection speed)

Joe Odyssey Rider

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Pilot Engine rebuild
« Reply #3 on: January 29, 2004, 09:51:10 AM »
I assume that the bearing was cold and the housing was hot? Since you were handling the bearing? THAT WAS IMPRESSIVE!

ludedude

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Pilot Engine rebuild
« Reply #4 on: January 29, 2004, 05:00:29 PM »
Yup the bearing was left outside...it's been COLD here :) The cases were heated ;)

ludedude

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Pilot Engine rebuild
« Reply #5 on: January 31, 2004, 06:48:41 PM »
Well the bottom end is almost together... I didn't get the clutch side bearing on all the way when putting that case half on. I made a puller similiar to what Big Tom did, and pulled the crank INTO the bearing. So then there was about 1/2-3/8" gap. But if I tighten the case bolts, the crank won't turn....now what? :?

PJ ENGINEERING (PROX)

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Pilot Engine rebuild
« Reply #6 on: February 01, 2004, 08:14:06 AM »
Hi try striking the crank on the ends this will line up the bearings, use a copper malet.

If that don't work post some photos and i will advise you .

Yours Paul v

ludedude

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Pilot Engine rebuild
« Reply #7 on: February 01, 2004, 09:25:21 AM »
What do you need for pictures?

There's some in my rebuild album:

http://www.45thparallel.net/coppermine_dir/thumbnails.php?album=12

PJ ENGINEERING (PROX)

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Pilot Engine rebuild
« Reply #8 on: February 01, 2004, 11:35:34 AM »
Hi what i mean by photos is of the crank the crank case view FROM the top where the cylinder fits on the see if the crank is over to one side or if the crank is to wide ??

Did you have the Crank rebuilt ??? Is it the same width ??

The way i buld my pilot Engine is

1 Press bothe the bearing on to the crank shaft and then CHECK for ture.

2 Warm up the RH case then lower the crank in to the case, let it go cold.

3 Put the 2 dowels in and the gasket on to the RH case.

4 Warm up the LH case and DROP it on to the RH case let it cool then put all the bolts in.

5 Strike the crank so that is in the centre of the cases, now go and CHECK the bolts for Torque.

This way you have not put any stress on the cases or on the crank, If you don't have a press you can put the bearings in some twostroke oil in pan and boil them to get them hot and then DROP them on to the crank shaft.

Hope this helps .

ludedude

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« Reply #9 on: February 01, 2004, 11:44:22 AM »
I will put the bearings on the crank first next time. :oops: Read about puttin ghtem in case halves then on the crank.

The crank was rebuilt by PCP Offroad, so it should be fine.....

How to proceed FROM here....How can I best remove to start again?

PJ ENGINEERING (PROX)

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Pilot Engine rebuild
« Reply #10 on: February 01, 2004, 12:52:46 PM »
so am i right in saying the crank case halfs are together ?? but with a gap in them ??

Or you have no gap but when you do up the bolts the crank won't turn ??


Don't worry about the way you have done it that is how all the manuals tell you but it not the beat way :roll: .

I wished i was just down the road i would come and help you :cry:

i build about 8 Two stroke engines a week so have a lot more experience with them .

Yours paul

ludedude

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Pilot Engine rebuild
« Reply #11 on: February 01, 2004, 01:19:05 PM »
Quote from: "PJ ENGINEERING (PROX)"
so am i right in saying the crank case halfs are together ?? but with a gap in them ??


Yes, about 1/4"

Quote
Or you have no gap but when you do up the bolts the crank won't turn ??


If I bolt it up, the crank will not turn

PJ ENGINEERING (PROX)

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Pilot Engine rebuild
« Reply #12 on: February 01, 2004, 02:08:52 PM »
Ok it could be that the crank is not pulled up to the bearing all the way use a stack of sockets as packing and use a bolt to pull it in more if you can, when you tighten up the nut give it a tap with a hammer if the bearing is not all the way home the nut will come lose when you hit it with the hammer.

The only other thing it could be is the crank has been built to wide this may be the case if you look here in your photo you can see the crank pin is not flush with the cran web it is under that is why i think it may be to wide but you will have to mesure across the crank webs to see if it is to wide.

Back over to you

ludedude

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Pilot Engine rebuild
« Reply #13 on: February 01, 2004, 02:50:19 PM »
So that's supposed to be flush?

I have a piece of pipe and the clutch bolt, that's what I used to pull the crank in the rest of the way...it seemed to come up solid so I assumed it was in all the way,and the case was not on all the way....will try again and tap with hammer on the head of the bolt and see if it comes loose. I have a puller to pull the opposite side case off, so if I need to I can do that. But for this side...I may need to go to a press and press this ide back out...if I end up HAVING to go there.

PJ ENGINEERING (PROX)

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Pilot Engine rebuild
« Reply #14 on: February 01, 2004, 03:20:21 PM »
Quote from: "ludedude"
So that's supposed to be flush?


Most of the Pilot crank i have built they are flush or just sticking out

Try putting you tube back on and tighten it up then give it a bash see what happens, if the tube comes lose you know you have moved it.