DIO Piston Install TIPS
These are some tips on installing or taking off your two stroke pistons
from the crankshaft. Always keep the parts clean and take your time and do
the job right. Remember that the piston always goes on with the arrow on
the piston crown, pointed towards the Exhaust port. Put your rings back on or take
them off with a piston ring expander. Rings are very brittle and can snap
in half, very easily. Line the rings up with the single ring pin in each
slot. Oil the rings and cylinder walls with two stroker oil and carefully
lower the cylinder onto the piston. Use a new base gasket , scraping off
the old one. When changing or working with the cylinder off, stuff the
crankcase around the crank rod to stop foreign debris from entering and
fallin in the crank well. Use a new head gasket every time and torque the
head bolts in a cross-hatch pattern to avoid warping the aluminum head.
Take your spark plug and screw it into the head before installing to make
sure the plug sits flush with the top of the cylinder head chamber.
DIO Cylinder Head Dynamics
After market dio heads are all a little different and it is very important
that you have the right plug length for the depth of the cylinder head.
Water cooled heads take a longer plug than the air cooled ones. The point
of this video is just to take your plug and make sure the plug seats well
and is not to deep or too short for your particular head. Remember all the
parts are different and checking them does not cost a dime and could cost a
motor. Dont guess when a question could cost you nothing to ask. RH
Moped Crank Bearing Removal
Just showing how you can use the bearing splitter sold by harbor freight to
replace bearings on your moped crankshaft.
As you can see the Puch e50 crank I was using was rusted as all hell so it
doesn't get much worse then that and I haven't had any difficulty.
how to install motorcycle crank bearings
never hit the bearings, even if you use a block of wood with it or a rubber
mallet, these cases are designed very precise for this, If you do this job
I recomend using an oven or a propane grill (top rack only) to heat these
cases. Also since you shouldnt put an open flame on your new bearing stick
the crank in the freezer that will cause the crank to shrink ever so
slightly and it will slide into the WARM bearings. Sounds crazy but if your
crank doesnt spin right or you have premature bearing failure, you will
relize why this is done. Yes you can use open flame on the cases if you
prefer but dont use it on the bearings. Make sure you remove the seals
before you do this too.
Yamaha YZF R1 crossplane crankshaft technology explained
The crossplane or cross-plane is a crankshaft design for V8 engines with a
90° angle between the cylinder banks. The crossplane crankshaft is the
configuration used in most V8 road cars.3d model of a cross-plane
crankshaft demonstrating the 90 degree angle between the crank throws and
the large counter weights.The crossplane crankshaft has four crankpins,
each offset at 90° from the adjacent crankpins. The first and last of the
four crank pins are at 180° with respect to each other as are the second
and third, with each pair at 90° to the other, so that viewed from the end
the crankshaft forms a cross. The crankpins are therefore in two planes
crossed at 90°, hence the name crossplane. A crossplane crank may have up
to five main bearings, and usually does, as well as large balancing
weights. Crossplane V8 engines have uneven firing patterns within each
cylinder bank, producing a distinctive burble in the Exhaust note, but an even firing pattern
overall. Their second-order balance, owing to the 90° bank angle and 90°
throws, means no additional balance shaft is necessary to achieve greater
smoothness. Without the 90° bank angle, a balance shaft may be required.
The other prominent design for a V8 crankshaft is the flatplane crankshaft,
with all crankpins in the same plane and the only offset 180°. Early V8
engines, modern racing engines and some others used or use the flatplane
crankshaft, which is similar to that used in a straight four or flat-four
engine. Flatplane V8 engines may use any angle between the cylinder banks,
with 60° and 90° the most common. They lack the V8 burble and the
superior mechanical balance of the crossplane design, but do not require
the large crankshaft balancing weights. Inherent balance of the big ends is
like a straight four, and modern designs often incorporate a balance shaft
for smoothness. But without balance shafts, flatplane designs have the
least flywheel effect of any V8s, which allows them to be more
The crossplane design was first proposed in 1915, and developed by Cadillac
and Peerless, both of whom produced flatplane V8s before introducing the
crossplane design. Cadillac introduced the first crossplane in 1923, with
Peerless following in 1924.
Inline-4 engines can also use the crossplane concept. The 2009 Yamaha
YZF-R1 motorcycle uses the crossplane crankshaft and, in the absence of the
90° bank angle of the V8, must use a separate balance shaft geared off the
crankshaft to eliminate the inherent vibration (a primary rocking couple)
found in this type of crank.
A crossplane crank has been used in Yamaha's M1 MotoGP racing models in the
past. Yamaha claims advances in metal forging technologies make this a
practical consumer product.
$5 Bearing Separator
This is a bearing separator I made from some scraps around the shop... Ok
it was more than $5 including the hose clamps and socket head screws... but
not by much...
Many of you have seen this one before. I apologize if bringing it back
Domestickilla gave me a crankshaft, and it's a nice one that I want to
clean up and use again. You'll be seeing a lot of it and because of this,
this video deserves to be here. I fixed what I broke, and this was my
In this video Ballos Precision Machine demonstrates magnetic dye penetrant
testing, crankshaft polishing and inspecting the balance of a "butchered"
4g63 6-bolt crankshaft.
T84J - Disassemble Main Drive Gear
Disassemble Main Drive Gear. Remove the snap ring and the 13 rollers from
the main drive gear. According to Joel Gopan, the snap ring is not
absolutely required but it does control the movement of the roller
bearings. I know that my experience has shown that the three transmissions
I worked on did NOT have the snap ring in place. You will also remove the
snap ring on the bearing side of the gear. After removing the snap rings
(including the one on the bearing as your new bearing may not have this
large snap ring; use a block of wood, a vise and a hammer to gently knock
the bearing from the shaft.
GASGAS TXT Pro New-type crankshaft bearing installation tips
NOTES: Before you attempt this work, please read all of this information
Jim Snell from GasGas in the USA explains how to properly align the
new-type crankshaft bearing and seal assembly.
This also applies to updates for the older model Pro engine.
IMPORTANT NOTE ABOUT THE MAGNETO SEAL: when doing this work, when using new
or your original engine cases, always remember to also install a NEW OUTER
MAGNETO-SEAL on the (left-hand) magneto side engine case. This seal goes
into left engine case-halve from the inside BEFORE the bearing is
installed. (In this video, Jim is using a set of new engine cases to show
the markings and bearing position and the seal is not shown. In the new
cases featured in the video for demonstration purposes, there is not a
magneto seal installed.)
IMPORTANT NOTES ABOUT THE REMOVAL OF THE CRANK BUSHINGS IF YOU ARE UPDATING
AN OLDER ENGINE TO THESE NEW TYPE SEALED BEARINGS: When updating an older
PRO engine, the crankshaft outer "seal bushings" must be removed from each
side of the crank "spindles". These bushings are pressed-on and have an
o-ring underneath. These bushings and o-rings will not be re-used. These
bushings are installed with an interference fit. To prevent damage to the
crankshaft, we recommend that you address this removal by the method shown
in this video or show this video to a competent mechanic who is familiar
with pressed-on parts of this type. This way, regardless of who does the
work, it is done properly.
Or see your GasGas Trials dealer to do this work for you.
Music by Kevin MacLeod - (incompetech.com) Licensed under Creative Commons
"Attribution 3.0" http://creativecommons.org/licenses/by/3.0/
Blueprint 104 - The Crankshaft
It's important to know what you've got even before dealing with the
machinist. If you want to inspect a crankshaft, this is how you do it. I
detail the process of removing the crank and what to measure. All
specifications in this video are illustrated with a 6-bolt 4g63 turbo block, but are all actually the same for
7-bolt engines with the exception of the rod widths.