2019 Hawk, ~700 miles, broken exhaust valve - Page 2

franque · 06-12-2020, 04:08 PM

Piston is separate, it and the wristpin are easy to replace.

youreekaa · 06-12-2020, 06:18 PM

hey. is there a shop manual link or PDF someone could share? working through my engine teardown now, and running into a few head-scratchers. (like why is the starter not coming off easily?) I'm not having any luck searching here or in the usual interwebs locations...

all help and guidance is appreciated!

Megadan · 06-13-2020, 01:36 PM

Quote:

Originally Posted by youreekaa

hey. is there a shop manual link or PDF someone could share? working through my engine teardown now, and running into a few head-scratchers. (like why is the starter not coming off easily?) I'm not having any luck searching here or in the usual interwebs locations...

all help and guidance is appreciated!

The closest I have found is the manual for the original Honda CG125. It is close enough that any semi-competent mechanic could figure the small stuff it doesn't cover from there. Don't worry, it is in English lol. http://die-kleinkraftrad-ig.de/wisse...itungcg125.pdf

As far as the starter being stubborn. The O ring seal of the starter to the left side case can be very tight. It's almost easier to pull the side case first and then remove the starter lol

youreekaa · 06-13-2020, 03:30 PM

yeah, I muddled through and got the crankcase apart. (a couple of side notes below on some stumbling points during disassembly.) I thought I'd attach a couple of pics from the carnage that has reached into the case. bottom side of piston, metal chunks in case (very evident) and finer metal pieces(not as evident in the pics). I have asked the dealer to send me an engine assembly as I'm not really confident that I can get all the metal out, even if I replace most to all bearings and internal parts. we will see how they respond.

Notes on disassembly:
-starter cover o-ring was tight! need a screwdriver and some force to pull that back
-flywheel puller is needed. crank bolt needs to be removed, but three allen head bolts do not. they seem to be made of brass, so their removal in one piece is damn near impossible anyways.
-still can't figure out how to pull of aluminum cap from back side of crank. this will be needed to remove the clutch, and it seems to require some sort of 4-pronged spanner-type special tool. anybody's experience with this is welcome for sharing.
-the rest is relatively easy to get stripped down. lots of 8mm and 10mm bolts, so a screw gun is much appreciated.

herbie · 06-13-2020, 05:40 PM

I have a new piston, pin with clips, and rings if you want them. Free for the asking, just PM me with your address.

Megadan · 06-13-2020, 06:08 PM

Quote:

Originally Posted by youreekaa

-flywheel puller is needed. crank bolt needs to be removed, but three allen head bolts do not. they seem to be made of brass, so their removal in one piece is damn near impossible anyways.
-still can't figure out how to pull of aluminum cap from back side of crank. this will be needed to remove the clutch, and it seems to require some sort of 4-pronged spanner-type special tool. anybody's experience with this is welcome for sharing.

- The inner allen bolts are there to secure the starter sprag to the flywheel. No need to remove them as you found out.

- The 4 pronged castle nut you mention is found on Honda bike engines from the dawn of time until today. More than likely a 20 or 24mm in this case, which is why there are so many of these tools on the market. https://www.amazon.com/Bipolar-Clutc...52Y356V2B7KQPY

Rokoneer · 06-13-2020, 08:01 PM

Gotta admit, and not trying to mock this issue at all, the picture of the head of the valve wedged into the piston is just amazing. New screensaver!

Cravin01 · 06-13-2020, 08:42 PM

That's so rare that it has never happened to anyone on this forum that I can recollect. I would push for the new motor also. I know where a Bashan Storm motor is for sale also...just an option but get them to replace it!

Megadan · 06-13-2020, 11:05 PM

Quote:

Originally Posted by Cravin01

That's so rare that it has never happened to anyone on this forum that I can recollect. I would push for the new motor also. I know where a Bashan Storm motor is for sale also...just an option but get them to replace it!

I have seen it one other time, and it was on a 2017 Hawk. The dealer, TXPowersports, wouldn't replace the engine and would only send him a cylinder, head, and piston kit. A few months later his engine grenaded itself and he ended up having to buy a new one. The members here all pitched in on a gofundme to help him raise some of the money for it, which I believe we covered about 300 of the 500 needed.

youreekaa · 06-14-2020, 11:22 AM

hmmm....

RedCrowRides · 06-14-2020, 12:35 PM

Seems to me like you are doing a lot of work solely due to the Seller not wanting to honor a 100% valid warranty issue and claim. If it was me i'd put the pieces in a box and ship it to them requiring signature upon reciept, if they dont want to send you a new engine, they can damn well do the work themselves and send it back repaired ready to go at no charge. , with Warrant on it and their work restarting at the time it is recieved by you as repaired. But then my Uncle is a Lawyer so I get free legal work so I can afford to not take $%^& off idiots and instead give it right back to them.

At any Shop i know of the Labor for this would dwarf the actual cost of the parts and you are being made to do it free , in fact at Manufacturer actual cost i'd guess that the Labor at a Shop for the job would likely be more than the replacement cost of the entire engine. and as i said before, i sure dont see how this isnt a valid warranty claim but i understand you not wanting to " Name names " until you hit that wall, but it sounds like you are getting " Manny"'d to me. Just sayin'.

youreekaa · 06-14-2020, 12:55 PM

thanks for the response. I certainly recognize the difference between what is right and what is legal. I'm stopped while waiting their response.

I've gotten a lot of my labor into this so far, and even a few bucks in tools. yeah, i'd rather be riding than messing with a 2 month old bike. but it is what it is at this point.

Cravin01 · 06-14-2020, 02:05 PM

Quote:

Originally Posted by Rokoneer

Gotta admit, and not trying to mock this issue at all, the picture of the head of the valve wedged into the piston is just amazing. New screensaver!

I was thinking the same thing. Makes the aluminum piston look like butter, I'd like to see the bottom of the head.

Sport Rider · 06-15-2020, 10:00 AM

happened to my friend who bought a 16 model after seeing and riding mine. he was out in Colorado doing a back country ride when he lost his valve.

duck9191 · 06-15-2020, 12:03 PM

Quote:

Originally Posted by youreekaa

thanks for the response. I certainly recognize the difference between what is right and what is legal. I'm stopped while waiting their response.

I've gotten a lot of my labor into this so far, and even a few bucks in tools. yeah, i'd rather be riding than messing with a 2 month old bike. but it is what it is at this point.

Looks like your in MI, if you are anywhere near Port Huron i should have that clutch tool you could use.

06-13-2020, 05:40 PM	#20
herbie Join Date: May 2019 Location: Illinois Posts: 864	I have a new piston, pin with clips, and rings if you want them. Free for the asking, just PM me with your address. __________________ 2022 Venom KPR 200 Red- the fastest color 16t and 46t sprockets, NGK Iridium CPR8EAIX-9, aftermarket full exhaust system. Top speed 81GPS 2023 Venom SS3 KP mini 150– Nibbi carb, Nibbi air filter, aftermarket muffler, decat 2022 Venom Ghost chopper 250 1997 Honda GL1500 Goldwing 1978 Kawasaki KL250 https://youtube.com/@herbiesgarage681
	1

06-13-2020, 08:42 PM	#23
Cravin01 Join Date: Jan 2018 Location: Forney Texas Posts: 498	That's so rare that it has never happened to anyone on this forum that I can recollect. I would push for the new motor also. I know where a Bashan Storm motor is for sale also...just an option but get them to replace it! __________________ Visit me on YouTube at "Project Next"! https://www.youtube.com/channel/UC6KTCi2GVbfRDv-2XCqHhsg?view_as=subscriber 2017 Bashan Storm Keihen PZ30 Pumper Carb,115 main jet,35 pilot jet, gutted factory exhaust, Sambo Digital Speedometer,LED blinkers, H4 headlight,D.I.D X-ring chain 428,17/42 sprockets,UNI cone filter.
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06-14-2020, 12:35 PM	#26
RedCrowRides Join Date: Jun 2018 Location: Florida Posts: 759	Seems to me like you are doing a lot of work solely due to the Seller not wanting to honor a 100% valid warranty issue and claim. If it was me i'd put the pieces in a box and ship it to them requiring signature upon reciept, if they dont want to send you a new engine, they can damn well do the work themselves and send it back repaired ready to go at no charge. , with Warrant on it and their work restarting at the time it is recieved by you as repaired. But then my Uncle is a Lawyer so I get free legal work so I can afford to not take $%^& off idiots and instead give it right back to them. At any Shop i know of the Labor for this would dwarf the actual cost of the parts and you are being made to do it free , in fact at Manufacturer actual cost i'd guess that the Labor at a Shop for the job would likely be more than the replacement cost of the entire engine. and as i said before, i sure dont see how this isnt a valid warranty claim but i understand you not wanting to " Name names " until you hit that wall, but it sounds like you are getting " Manny"'d to me. Just sayin'. __________________ 2001 Mustang GT 2004 Sportster 2018 VADER 2020 Orion RXB250L
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06-12-2020, 04:08 PM	#16
franque Join Date: Nov 2017 Location: Marseille, France -> Conakry, Guinea Posts: 1,481	Piston is separate, it and the wristpin are easy to replace.
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06-12-2020, 06:18 PM	#17
youreekaa Join Date: Apr 2020 Location: SE Michigan Posts: 21	hey. is there a shop manual link or PDF someone could share? working through my engine teardown now, and running into a few head-scratchers. (like why is the starter not coming off easily?) I'm not having any luck searching here or in the usual interwebs locations... all help and guidance is appreciated!
	0

06-13-2020, 08:01 PM	#22
Rokoneer Join Date: Feb 2020 Posts: 11	Gotta admit, and not trying to mock this issue at all, the picture of the head of the valve wedged into the piston is just amazing. New screensaver!
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06-14-2020, 11:22 AM	#25
youreekaa Join Date: Apr 2020 Location: SE Michigan Posts: 21	hmmm....
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06-14-2020, 12:55 PM	#27
youreekaa Join Date: Apr 2020 Location: SE Michigan Posts: 21	thanks for the response. I certainly recognize the difference between what is right and what is legal. I'm stopped while waiting their response. I've gotten a lot of my labor into this so far, and even a few bucks in tools. yeah, i'd rather be riding than messing with a 2 month old bike. but it is what it is at this point.
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06-15-2020, 10:00 AM	#29
Sport Rider Join Date: Jan 2016 Location: Mooresville NC Posts: 2,038	happened to my friend who bought a 16 model after seeing and riding mine. he was out in Colorado doing a back country ride when he lost his valve.
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