Adventure Bike Rider Forum

It's a steep learning curve but you're doing well at it ! (thumbs)

The bag of goodies arrived from Huskysport today and the new carb hoses.

The flywheel has been transferred from the old motor to the new.

The rear swingarm has a nut on the end of the axle bolt... there's a novelty :whistle:

The tank can now hang on two hangers rather than just the one.

New pads in the front caliper and the caliper bolted back on... does seem to be binding a bit

And the rear subframe and air box have had a clean and been refitted.

I've ordered a short piece of silicone hose that has an internal diameter of 60mm to hopefully solve the carb manifold conundrum, I'll know more when it arrives.

To get the flywheel nut torqued correctly I had to take the transmission cover off and wedge a soft washer in the teeth of the primary gears and then I had to download the user instructions for the torque wrench...

Flywheel on, then the flywheel cover and the transmission cover... so far so good.

Now to the clutch cover which wouldn't fit :blink: so I pulled the rod out of the middle and it's about 5mm longer than the one from the old engine :dry:
What to do...

But the clutch cover is on the engine in the pic you first showed the new engine.
Surely there must be some mistake ?
Or is the operating cylinder not going on ?

You're quite right!

The small operating cylinder, the cover on the end of the braided clutch hose.

This one...

Try taking the cover off the master cylinder, maybe too much oil in there.
You have to push it on a bit but make sure you do it straight. (you can use the bolts doing it but you'd have no feel doing it that way.)

Thanks for your input Dutchgit.

I've sent an email to Huskyparts and I'll phone Huskysport in the morning before I get heavy handed.

Don't forget the gasket !

Having been a bit dim I have now seen the light...

It dawned on me that a clutch actuator hose being braided was a dead giveaway for "quite a bit of pressure needed" to push that rod through it's little hole and no amount of pushing it with my thumb was going to make the slightest difference...

I also noted that each rod in it's respective engine stuck out by the same amount.

As you said Dutchgit, I reassembled the cover and the piston, not forgetting the little rubber o-ring, and bolted it back on, job done. (thumbs)

The decompressor cable has been hooked up, the rear brake pedal and cylinder connected, the kick start... ooh temptation , new radiator hoses on, new chain rollers as the old ones had completely seized just like the chain guide which I still need to replace, and finally the oil filters removed cleaned, last remaining dribbles of old oil out and the paper oil filter removed ready for a new one!

I haven't looked at the new chain yet but imagine I'll have to split it to get the correct length?! Can anyone recommend a good chain tool???

Fill the oil filter with oil before you fit it or it might expand, making it more difficult to get next time.
If you use a grinder to grind off the little stub ends you can use a small punch to separate the chain. Easiest is to use a separable link if you don't want to invest in tools. (Carry a spare link on the bike)