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Makotosun

Split the case and some metal balls fell out, where do they go?

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I gotta hand it to you Sherka, you've got more guts then I do, my rod needs to be replaced in my DT400 and I'm just too afraid to do it and not be able to get the transmission back together, all those gears just have me too nervous to try...
2023 Tenere T7
1976 DT400C
1975 DT400
1981 DT175H
1972 DT2 250
1980 GT80
1972 JT2
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02 Dec 2022 16:59 #21

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  • Sherka
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Well thank you man. I daily drive a 1987 Toyota Troopcarrier, the ones you see in safaris or isis driving around on the news. Picked it up 3 years ago when I was 17 as the cheapest one for sale in America as the previous owners (who were a terrorist organization) didn't take the best care of it. Spent 6 months rebuilding most everything mechanical in it besides the front axle and have now driven it to California and back 2 times with my best friends. I figured with a combination of youtube, factory service manuals, and online forums I'd be able to do it and I did! But just like now, half the stuff I did I had to tear all apart again and reassemble it just cause I missed one little stupid thing (like crank washers). As I've seen in the landcruiser community, and now this forum aswell, there's tons of people out here who are willing to help or share their knowledge, its how I basically do anything haha

imgur.com/a/GHiWUVY
Last edit: 02 Dec 2022 17:13 by Sherka.
02 Dec 2022 17:10 #22

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As far as cars go I can take an engine apart and put it back together then make it run no problem, even supercharged my Challenger (had to have a tuner tune it though), just don't trust myself with the innards of the transmission on the bike.
2023 Tenere T7
1976 DT400C
1975 DT400
1981 DT175H
1972 DT2 250
1980 GT80
1972 JT2
The following user(s) Liked this Post: Sherka
03 Dec 2022 02:08 #23

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I was equally concerned I wouldn’t be able to get it back together when I did my CT3. It’s actually not as hard as it seems. I watched some you tube videos several times and got comfortable with the concepts. I wouldn’t hesitate to tackle this again. Lots of photos. Bagging parts in separate bags by worked area on the engine. Definitely need a tusk crank installation/puller. Just be very systematic and you’ll be surprised how easy it is. 
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03 Dec 2022 12:01 #24

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I started woffling so don't take too much notice of me lol.

I know Partzilla shows a washer on the left side but i'm not sure the reason as crank is held tight to the right side with washer to keep flywheels from touching the case--as you found out--. On the left there's a slight gap. So maybe 'that' washer is there incase the complete crank--with right side bearing--decides to move to the left if the right side bearing isn't tight enough in the case. In theory that left side washer is just cruising along free spinning on the crank. Unless you drive the left bearing over to load the washer. I've not had a smaller motor apart for years but don't think my 360 has a washer on the left side & same setup, just bigger. I guess if you pressed the left bearing with washer completely up to the left crank wheel then fitted it all into the right bearing--crank is a sliding fit into 'that' bearing', then heated the left case to fit on & it would stay tight against the washer. Ok never mind lol. Too much information.
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03 Dec 2022 13:17 #25

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RT325, I agree left washer/shim doesn't make sense but some models do have them. 

Later model 175's had the "washer" machined on the crankwheel so no loose shims to forget to install... which is something I've done at least a couple times. 

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1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
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03 Dec 2022 14:37 #26

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Tony you can split your cases not as bad as you think if you can rebuild a challenger engine you got it
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03 Dec 2022 15:24 #27

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Thanks for encouragement guys, will mull it over in my head. It would save me a big chunk of change for sure!
2023 Tenere T7
1976 DT400C
1975 DT400
1981 DT175H
1972 DT2 250
1980 GT80
1972 JT2
The following user(s) Liked this Post: Sherka
03 Dec 2022 15:37 #28

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You could also download the free manual on this site . Go to the tech page on the task bar, download it and save your self loads of grief by reading and looking at pictures of the parts and images therein . It's okay watching you tube as long as you're not watching a knobber who's answer to everything is force instead of brains.
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04 Dec 2022 16:26 #29

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  • Sherka
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Yea, I didnt even take all the gears apart, just took them out as a whole and all assembled. Really now that I "kinda" know what I'm doing I was able to tear everything down and put it all back together in 3 hours total. First time probably took me 6 hours just cause everything was so new, but then with the knowledge of how everything went together I knocked it out.

So the crank shims fixed the seizing of the crank but now I have another issue. This gear right here with whatever this bearing retainer or whatever it is has play side to side in it. Thus causing it to hit the bearing retainer and stop everything from rotating. Heres a video, and some pictures
www.youtube.com/shorts/iMokMMfl_Qo
imgur.com/a/OCWPAqj

My question is... is there supposed to be this much side to side play in that gear? Am I missing yet something again, and how important is it to run that "retainer" Dont know why I'm having issues with it just now 
05 Dec 2022 09:05 #30

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