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Discussion Starter #1
Alright well I fell victim to the previous owners shit maintenance with their chain and now have a lovely hole in the motor. Seems the general consensus is to split the cases and have it welded. I'm relatively mechanically inclined so I think I can do it. I already downloaded a service manual, any other tips anyone can offer? Seems like this is the most active R6 forum I've seen.

Some pics:





I'll probably use this thread to document the process and for my own sanity.
 

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Its easy to blame other people when shit happens. How long did you have the bike before it happened. Chain looks really dirty, even the swingarm bolt looks rusted. If you bought the bike like that you should've done some maintenance on it. Clean the bike, adjust chain, even change it if the bike is older and have some miles on it


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Discussion Starter #4
Its easy to blame other people when shit happens. How long did you have the bike before it happened. Chain looks really dirty, even the swingarm bolt looks rusted. If you bought the bike like that you should've done some maintenance on it. Clean the bike, adjust chain, even change it if the bike is older and have some miles on it


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Oh I do take some accountability, I had it only for a year, I should have just replaced the chain from the jump. As far as cleaning/lubing/adjusting goes I had it adjusted pretty well, and lube it once a week. The rust you see isn't from the bike itself, it's from the steel crash cage that was on it. I know the previous owner isn't totally at fault, I take responsibility for my **** ups. But the previous owner wasn't exactly a mechanical genius, the first thread I ever posted on here was when I was blowing wheel bearings because the previous owner had removed the axle spacer tube.
 

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what sucks is someone used to make a billet chain guard to replace that soft rubber one. but I can't seem to find it.
They made them for 3rd gens, but the only ones that were made to fit a 2nd gen were for the mini car guys, and the counter shaft sprocket had to be a 14 tooth for it to fit. Which sucks because it was the 2nd gen that had issues with keeping sprocket nuts on, so that is the model that needed it....
 

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well I doubt the owner (boss) would let me use it on a weekend without anyone else there. he's not all that nice of a guy.
I've made things in the past but they were on my lunch break. very small quickly made parts that took me a week to make. the problem is that kind of a part would take that machine probably 6 hrs to cut. that machine can't be left running unattended such as overnight because it throws the tool coolant on the ground. (shitty design) if it runs out of coolant it will break a tool or ruin the part. and I have no bike to take measurements from and test fit. I have a 2015 R1 now and sold my R6.

I've thought about talking to him about making stuff when we are slow. such as brake levers, rearsets, clip ons, maybe engine covers. I'm not as good with the cad software as the other guy there so I'd have to get him to design all the stuff. and I can't afford that software to use at home (it's $7k) so we can only use it on 1 of the computers we have at work. due to licensing bs.
I really wish I could make you something but I honestly couldn't due to those reasons. if I had that bad boy at home I could.
 

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Discussion Starter #12
Well yesterday I started on the adventure. Got the garage all set up and started digging into it. Learned a few things too like the fact that there was already one broken exhaust stud, and now there were 2 more. Really frustrating too since I had the nuts/studs soaking in acetone/atf mix and heated the shit out of the stuck ones only to still snap them. Oh well, looks like I need to get a stud puller and can fix all three at once.

Full disclosure, this is the first bike motor I have ever dropped and dug into, unless you count my CRF 50. :p So it's going to be a slow process for me, and honestly not sure how it will turn out.




Broken studs:



Also found this on there, I'm told it was a "luck" thing.




This is where I left it last night.



Struggling to get underneath the throttle bodies to get to their clamps. I can see the outside ones but can't get in well enough to turn them much. I ready that a ball end allen wrench will be best for this so I went to HD this morning and got me a nice long ball end ratchet set. Going to give them a go tomorrow night.

Was considering dropping the motor with the TB's still on, but not sure if it will clear the frame. Anyone know?
 

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Discussion Starter #13
Welp got the motor out! Now begins the real fun.






Definitely will need a better jack and some help to get the motor back in. Next step is pulling the trans out to get to the bearings where it will need to be welded at.
 

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Discussion Starter #14
Going to be starting this back up soon. It's been sitting for a year because I had to get my truck ready for a cross country trip to wheel Moab.
 

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Discussion Starter #16
Not yet, but soon, very soon. Have the hole welded up, gotta get the motor back in. Had 3 broken studs to deal with, one ended up snapping flush, got one out with a stud extractor, and I'm going to try to weld a nut to the third one because the stud extractor won't grip.

Lot's and lot's of photos coming soon for anyone else who is going through this.
 

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Discussion Starter #17
After 3 years of neglect, here is finally the progress.

Got the throttle bodies off, and out of the way. Then I removed the shifter cover, the stator cover and the starter. This gave the welder plenty of space to get in there and close it up.

IMG_3342 by Michael Halat, on Flickr
IMG_3361 by Michael Halat, on Flickr

I cleaned the **** out of the spot as well as the piece that was supposed to be welded back on.


IMG_3342 by Michael Halat, on Flickr

In the end the welder decided to fab his own cover.

IMG_3354 by Michael Halat, on Flickr
IMG_3353 by Michael Halat, on Flickr

From there I went on to cleaning the left overs of the old gaskets and sealing everything back up.

IMG_3345 by Michael Halat, on Flickr

IMG_3360 by Michael Halat, on Flickr

After that I went on to pulling the snapped studs. One broke flush, another came out with the stud extractor.

IMG_3365 by Michael Halat, on Flickr
IMG_3364 by Michael Halat, on Flickr

The last one even the stud extractor couldn't grab. I decided to buy a Lincoln buzz box and learn how to weld SMAW to get the last one off.



Practiced on one I removed and then setup the real thing. The knife was a spacer to make the nut sit level.

Projects by Michael Halat, on Flickr
Projects by Michael Halat, on Flickr
Projects by Michael Halat, on Flickr

A couple tacks of 6013 and it came out. So stoked. Going to attempt to get the one that snapped flush, then putting it back together. If I can't get it I'm not super worried. The rest should keep the exhaust from leaking. Going to likely paint the tank and get new plastics, and then it's time to ride.
 

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I've known multiple Volar brand chains break. 1 guy got lucky and it just took out the water pump on his busa, the other guy on the R1 it put a hole in the case and bent the transmission shafts.
 
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