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Engine Rebuild step one

dazzanna

dazzanna

Joined Sep 2009
54 Posts | 0+
Australia
After two major disasters
1/ big end faliure
2/ the $3000 quote to fix it

I decided to venture of and the fix disaster myself ...........
and found s#*t loads of design faults which I intend fixing !

Falco 2000 by the way !

Ive started by getting the the crank machined and the rods rods
closed and tunnel bored.

Next.......... dremel in hand - fit Toyota 2k big end bearings !

Then modify mains as to fix the oiling problem the crank suffers.
.......Look up .... Design fault one !

Followed by a decent yet cheap mechanical with hydraulic advantage
timing chain tensioner .... Fault Two...

If someone can tell me how the hell to upload pics I'd offer my progress !!

Wish me luck
 
Last edited:
dazzanna said:
After two major disasters
1/ big end faliure
2/ the $3000 quote to fix it

I decided to venture of and the fix disaster myself ...........
and found s#*t loads of design faults which I intend fixing !

Falco 2000 by the way !

Ive started by getting the the crank machined and the rods rods
closed and tunnel bored.

Next.......... dremel in hand - fit Toyota 2k big end bearings !

Then modify mains as to fix the oiling problem the crank suffers.
.......Look up .... Design fault one !

Followed by a decent yet cheap mechanical with hydraulic advantage
timing chain tensioner .... Fault Two...

If someone can tell me how the hell to upload pics I'd offer my progress !!

Wish me luck
Click to expand...

Interested indeed man, best way to upload is to join 'Photobucket'and upload your pics there, under each pic you have there are options, in the IMG CODE box just copy and paste that onto your post and its all good.

Keep us posted with plenty of pics mate :thumbup

Best of luck my friend :eatcorn
 
Falco rebuild

From Australia !
V60 engines can't be bought here for a reasonable price !!! ( if at all ! )
And why buy another disaster ! ..
I'll post pics of my progress and mods ( Photo bucket ? - Tomorrow )

So many flaws ! so many easy fixes ----- I hope ----- Big ends good !!!

Luck !
 
I'm confused is the early Falco motor not the same as the early Mille as the early Tuono ??.
 
dazzanna said:
From Australia !
V60 engines can't be bought here for a reasonable price !!! ( if at all ! )
And why buy another disaster ! ..
I'll post pics of my progress and mods ( Photo bucket ? - Tomorrow )

So many flaws ! so many easy fixes ----- I hope ----- Big ends good !!!

Luck !
Click to expand...

Mate, another Aussie!! Dont suppose your in Melbourne by any chance??
 
My rebuild

If your interested in the costs so far ...
1/ Machine crank - shut rods and tunnel bore $165.00
2/ Toyota big end bearings ..... expect to pay $45.00
3/ I expect to to pay $20.00 for the manual over hydraulic timing chain conversion !

I'll keep you up to speed !
Email if you need more.......

Darryn
 
CIMG0269.jpg

CIMG0294.jpg


Good work man! :thumbup
 
The crank and the chain

The cranks done !
( Aprilia don't make under size bearings )

Manual timing chain adjusters / over hydraulic.
$15.00 .. Bargain .. May have to lower the spanner side yet !
"Gotta love those 16mm sump plugs from Repco"
The adjuster bolt will be cut to length as when I know the optimum size.
( when the engines together ) and a head fitted or slot cut into it !

"Foot note to fault 2" - who the hell puts a tensioner on the load side of a chain ? -

Next the main bearing on clutch side of the crank.
The oil feeder hole in the bearing is to be extended 1cm using a
dremel - "big ends need friggin oil man" ridiculous that the big ends get
oil pressure for a micro of a second every revolution !
dazzanna
[/IMG][/IMG]
 
Last edited:
Well done :thumbup Now this is what it's all about,too much of this ' what do you lot think of my shiny new levers' kind of thing.

As one that's not yet had the pleasure of seeing inside a Rotax lump,what is the crank problem? not enough surface flow to the journal? I assume from your comments you are going to run a slot in the journal from the oil feed hole?

Keep us posted please
 
Turns out

Turns out oil feed isn't an issue ! ( Oops )
Cranks on the back burner for a couple of days .... Not happy with the
machining ! .. need new rod bolts also ... Will be in contact with ARP Monday to
find an affordable automotive equivalent !

Noticed questions on this forum regarding stator pullers-

Grab an old cv from a automotive workshop ( check the size .. Duh )
Cut the stub off - find big nut- weld ----- hey presto !

"There are no problems - Only solutions"
 
Budget blow out

Re estimate of engine rebuild
inc new rod bolts
Timing chain tensioners .... Bargain $15.00
Toyota Big ends
Re machining .... again ...

...$500 usd
...Lots of those pommy pound things
...Or 15 cartons of Aussie beerdollars !

Upload progress Wednesday ....

Ontoit !
 
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