Engine strip down (1st time)

[fredperrybruce]

Hi, all

One hell of a mess up today, was Changing my clutch today for a new higher tooth cog (again) and managed to drop the wood ruff key inside the engine

So have dropped engine out already but need a fly wheel puller to split the cases.

Am pretty scared at the moment as already snapped one piston ring being to heavy handed which is in another thread.

Is there anything I should look out for in a engine split that may or could go tit's up for me as a amature vespa owner??

[stevievespa]

Ouch good luck mate dunno bout engine but ive got a flywheel puller if ya need it

[fredperrybruce]

Cheers steve, I've sent you a message on instant messanger . Lending me your flywheel extractor would be great

[vespasco]

It could well be a good idea to buy a manual, or better, the DVDs that show you how to do everything (they have good reviews), before you do anymore damage.
The basic 'special' tools dont cost too much.

[henri]

read sbwnics thread about splittin cases in the frame n adapt to being out , i went thru it n cud only find 1 very small memory slip n it made better sense than i can write , H

[sbwnik]

I meant to update that, but before you go digging, occasionally you can get a good result with a magnet on a stick when you do this... Been there, done that!
You'll need to pull the clutch out first though. But I assume that's not an issue....

[fredperrybruce]

I was taking the clutch out when the woodruff key fell out.

Not even sure it went into the engine but I can't find the dam thing anywhere and I darn't risk running the engine knowing it could be in there!!

[sime66]

You have said that you’ve already taken the engine out? Disconnected from everything and removed from scooter? Lets be clear on that first – by the way, it probably wasn’t necessary.
You’ve also got your clutch and cylinder head off already, broken the rings and lost the woodruff key, possibly in the engine.
You can’t do any more damage yet because you can’t get the flywheel off?
Sounds to me like you want to use the break and read some books and watch some videos before progressing; and have a proper look for the woodruff key to be more certain you need to split the cases.
Even if you do just split the cases, retrieve the key and find no other problems, there’s stuff you need to have to hand to refit it all. (flyside seal, main gasket set, new clutch nut, woodruff keys come to mind, but you’ve yet to sort your rings (make sure there’s no bits of that missing) or inspect your piston/barrel either, then there’s tools and consumables for the job too). There’s also jobs/inspection you should do whilst you’re in there.
A bit of learning and preparation for the job before continuing is my advice……….
With the jobs you’ve done so far, you must have got Haynes by now? Scooter Techniques DVDs? At least watched a few Youtube videos?
Splitting the casings is a job that sort of grows once you’ve started it if you’re not careful – read my threads if you like; I’ve directed you to them before, so won’t link again here. I made plenty of mistakes in the first strip/rebuild that I wouldn’t repeat.
To save going onto the other thread, you asked about running in new rings – yes you do; 400/500 miles for my DR piston & rings, less for just rings (others will disagree, and you can take whichever advice you like when you get to it) but you’re a few jobs away from that worry anyway! - Try this thread:
vespa.proboards.com/thread/3127
(It's mainly been discussed before if you use the Forum search)

[fredperrybruce]

Here we go,,

Stevievespa lent me the fly tool last night so cracked straight on with taking the engine apart, took the fly wheel off and heaven behold 2 of the 3 screws holding the stator on was completely rounded off!!

After nearly throwing the engine across the garage the bloody key dropped out. happy days

Time to put back together me thinks, well after new bits arrive

[henri]

i hope ya goin to sort the stator screws whilst ya there ,i might be "fate-ing" ya ,but if left alone that sort of stuff comes back to haunt ya , the engines out an youve got good access so theres no better time to correct it , dremel or junior hacksaw blade a slot an get a impact driver on them , i usually replace em with cap head allen screws ,with a blob of thread locker /semi permanent ,
use a blob of locker on ya keys aswell , they dont fall out then an its easier for re-assembly , the key ya nearly lost , is it really loose in the keyway/slot ,it shud be a tight fit in the shaft an clutch body ,any slackness will allow movement an eventually damage to keyway=scrap crank ,or a sheared key an a "breakdown" ,scoot n maybe you 2, H

[fredperrybruce]

I've got 2 keys on order they are both well worn and need replacing. I was gonna leave the 2 rounded screws alone as I couldn't be arsed to muck around.

However I know it will come back and haunt me at some piont so will tackle next weekend.

[sbwnik]

You can't split the engine without removing the screws anyway. I've used small mole grips to grab the heads in the past, straight forward then. The one problem I do know about (second hand) with trying to cut a slot is that you can weaken the cap and shear it off. Rare, but possible, so be careful!

[fredperrybruce]

Decision made I'm going to bite the bullet and split the engine!!

I'm sure it's been well over due checking the engine by previous owners so while the engines out I'm gonna check seals & bearings.

As for the 2 screws with rounded heads on the stator I will try the mole grip method like sbwnik mentioned if that doesn't work, cut slots with a dremmel and try and unscrew them.

I'm not gonna rush this job as the scoots gonna be laid up for the winter anyway and I don't want to bodge or miss anything out.

cheers for the advice guys