The carbon on the pistons is built up from the burning of oil. The rear cylinder must of been leaking oil quite badly..

The circlips are what holds the pin on the piston. The should be replaced everytime but its not the end of the world if you dont (but only if they are not defromed from removing them). They WILL NOT come with the piston rings. They have to be ordered seperately.

__________________
Technician, BMW Chester Motorrad.
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

Now that's more information than I care for interpol to know :/

cleaning the gasket... getting ready for the parts.


i noticed that there's some scratches here. is it ok?


what about this? i think it's normal.

Those scratches don't look like they were done while the bike is running. They are in the wrong direction to start with...

The other marks are normal on a high mileage clutch.. As long as they are smooth ??

__________________
Technician, BMW Chester Motorrad.
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

Now that's more information than I care for interpol to know :/

Those scratches don't look like they were done while the bike is running. They are in the wrong direction to start with...

The other marks are normal on a high mileage clutch.. As long as they are smooth ??

Hi Ted! the second picture with the scratches looks fresh but im sure that when gary and i took out the clutch, we didnt 'scratch' it. what do u think might have cause this scratch marks?

the 3rd picture: the marks are smooth...so thats a good sign?

I wouldnt worry about them. They look like they are scratched from someone in the past installing or rolling around on a garage floor etc.. They won't do any harm..

__________________
Technician, BMW Chester Motorrad.
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

Now that's more information than I care for interpol to know :/

hi ted and all, the piston rings, valve stems+seals+guides, gaskets and clutch plates+disc has arrived. i had sent the valve set and the cylinder head to a workshop for alignment and installation.

will update on the good news!

remove and replace valve guides
hone guides to size
check new valves for run-out
machine valve seats using spec's from repair manual
check spring heights
assemble with new valves and seals.
cost: US$250-350
duration:3 days+

meanwhile, gary help me to hone the cylinder to fit the size of the new 0.25 piston ring that we ordered. after a few minute of work, we find that the 0.25 ring is too tight for the current cylinder. a few method we could get the piston ring fixed:

1) continue to hone the cylinder and take out more materials to fit the 0.25 rings and file the end of the rings to specification.
2) order a set of OEM (original) rings from singapore again. (got to wait)
3) purchase a set of OEM rings here in usa but the problem is:

can u advise me if the shadow 750 piston ring fits into my bike?
my VIN number is JH2RD07A9WM302728.

a kind soul from HUBB left a message for me:

Hi!
If you have covered such a high milage with a faulty air filter, probably you will need some new rings...it is a simple task, you will just have to deglaze the bore and fit some new rings. When you do that , just replace the valve seals and this should solve your burning oil problems. You can use Honda Shadow 750 rings and valve seals, since both models share those engine components ....and Shadow 750 was widely available in USA market...
It is :

13011MV1305 for the rings
12208-413-003 for intake valve seals
12209-413-003 for exhaust valve seal
World of Powersports w/ MC MART's 2000 Honda Street Bike VT750C SHADOW Parts Finder this is Honda Shadow in States...
Motorbike components for Honda XRV-750-W (G) this is Africa Twin in Europe...

what is your advice folks?

goh

I would get the original size Honda rings... Honing the bore to fit oversize rings is a bit crazy. You would actually need the cylinder PROFESSIONALLY bored out to fit the rings. Not just a guy with a hone tool on his power drill.

If the Honda Shadow shares the same cylinder size and piston, the original rings from that will work although I have no experience of this bike.

I say again, do not hone down and cut rings to fit the cylinder.. This is not good engineering.

David Silver Spares - PARTS

This guy does Honda parts. Maybe cheaper and faster to the USA than Singapore. ????

__________________
Technician, BMW Chester Motorrad.
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

Now that's more information than I care for interpol to know :/

thanks ted for that warning, we almost wanted to hone the whole cylinder down.

the issue is how do can we get to know if shadow 750 share the same piston ring with xrv750?

pls advise.

goh

They will probably share the same part number.

__________________
Technician, BMW Chester Motorrad.
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

Now that's more information than I care for interpol to know :/

Boom boom!

for the shadow that we going to order is:13011MBA305
for africa twin recommanded by prompp :13011MV1305

i think i gonna order it. US$43...get it by tomorrow 11am. gosh, US43!

we got the shadow 750 rings. about US$100 including tax and it DO NOT FIT AFRICA TWIN!
MR PROMPP, I HOPE U KNOW WHAT U ARE TALKING ABOUT.

end up, we need to file the oversized piston ring abit on one end but it fits perfectly.

then, when installing the whole cylinder, the cam chain sprocket that needed to be aligned could not be. we tried it many many times but it is not aligned so we suspected it may be the chain elongation over time that it is not aligned. anyway we have the same 'not aligned' for the front and rear cylinder.

later gota test ride the bike. my fingernails are very dirty now..

keep u guys update.

bike is done. had a hard 24miles hard run-in/break in.

will change engine oil and oil filter at mile 600.

rushing to rhode island from austin. got to b there at 25th july 09. will update on what had we done. thanks everyone!

i opened up the rear cylinder today, found that the piston is cracked, cylinder head is damaged. new valves were broken.


i got the bike running,`after 130miles, it stopped. went to dave's house, i open the rear cylinder it became like that.

im lost now... kind soul pls help