acftfliehr wrote:Dai,
That's what I was fearing... this is all my bad... I installed the pump assy with both gears in the pump housing... I should have installed the small oil pump driving gear into the engine case and lined it up with the offset notches of the output shaft, then install the pump assy (with the driven larger gear installed lining the large gear up with the small gear by turning the water pump impeller).
I've done this twice before on this very bike (Original owner)!!!! In this case in a time constraint hurry, thought the driving small gear was notched equally with the output shaft meaning it could only go in one way even though it could be 180 degrees either way!!! NO!!!! like the airheads Ignition trigger assy's the notches are offset!
I thought during the the assembly at the time of the Oil pump/water pump went in smoothly until it matted with the engine front case, the notches must have been 180 off!!!
When I went to start the engine it cranked over and started briefly, then locked up! Think the engine is toast!! I have a spare with 25K Miles on the clock, this one has 310,000 (but still going strong until this debacle)!!!!
I work as a Aircraft Mechanic and cannot believe I did this!!! And I know better.
Moral of the story!!! I was in a hurry to get this little job done as we have our national rally in Oregon this coming week.. wanted to ride the bike up and tried to fit this job into a tight work schedule!!!
I've been beating my self up these past few days mentally on how this could have been prevented, however, looking forward now to do the engine swap after the rally and will "Take my Time" Slow and methodical is good!!!
Taking My modified 1986 R80 to a 100RS to the rally. It will be cooler ride however... which is a very small benefit of this man induced disaster (in my head of course)!!
Don't be so uppity that a simple job can be done in a hurry!!!
Now that I've purchased a New R1250RT over this fiasco, plus a bit of free time after a busy summer, I started to tackle this and see if I could get that small gear out of it's bore. Success!!!
By using a Rolling Head Pry Bar (https://otctools.com/products/rolling-head-pry-bar-18-long) that was out of my dad's kit (whom has recently passed) I was able to pry it out with very little effort, using the oil passage way below the oil pump mount surface as a leveraging point (used the small 12" Bar) and the wee gear popped out just like that!
The replacement gear when properly aligned with the notch of the output shaft was very hard to push into the bore as the block bore was buggered up from the offset of screw up of install and then running it for a bit.
I Dremeled the areas that were protruding into the bore (cleaned it up) until it was smooth with easy easy installation of the gear.
Now I have to sell my original bike to someone who may be interested as I have too many bikes in the garage!!! Great bike for commuting and wanted to let the group know of how durable this machine is, even with a major screw up like I did and survived!
Was thinking of keeping the bike and selling the new one, but it is indeed light years ahead of the 1985 (my last new vehicle purchase). Bay Area Based!!! Set of Spare Wheels included and asking only $1000.00 to a good owner... Complete Maintenance records from Birth as well!!
Video of the beast after a 25 mile ride and ops check... since used it for my 50 mile round trip commute in the blistering 105 degree F weather!!
https://www.youtube.com/shorts/A0iEWcv9eDg?si=I6LT1O0G9k8_B9te
Oil-water pump impeller reluctant to come out Mon Jul 31, 2023 1:23 pm
