DB-06 4th Gear Clutch problem - Page 3

TheGammaGhost · 08-17-2012, 12:55 PM

okay cool, i did a few more measurements of where the bolts are at, and it looks like it will fit. Hope i don't have to remove the gas tank.

FastDoc · 08-17-2012, 01:06 PM

You will have to remove it but its simple. What is your concern?

SpudRider · 08-17-2012, 01:20 PM

Nice score on the parts bike, Gamma!

You will need to remove the exhaust header, carburetor, clutch cable, throttle cable, drive chain, fuel tank, et cetera, before you can remove the engine.

All of this is not difficult.

When you are ready to begin your engine switch, please start a new thread, and take lots of photographs.

We will help you when you have questions, and your project will be a wonderful resource of information for others in the future.

Spud

katoranger · 08-17-2012, 01:56 PM

Good score on a parts bike. Engine swap is not too bad. Should take an afternoon to get it done.

TheGammaGhost · 08-17-2012, 01:58 PM

Quote:

Originally Posted by FastDoc

You will have to remove it but its simple. What is your concern?

it's just one more thing, but after looking at it a bit more, it doesn't look to difficult.

Quote:

Originally Posted by SpudRider

Nice score on the parts bike, Gamma!

You will need to remove the exhaust header, carburetor, clutch cable, throttle cable, drive chain, fuel tank, et cetera, before you can remove the engine.

All of this is not difficult.

When you are ready to begin your engine switch, please start a new thread, and take lots of photographs.

We will help you when you have questions, and your project will be a wonderful resource of information for others in the future.

Spud

Will do spud, Ill make sure i take my time, and take a lot of pics.

Im so lucky to have found that bike on craigs. Once my bike is good to go me and my bro may throw my roketa engine into the other one and use it as a fun bike. :twisted:

Ill keep you guys updated.

FastDoc · 08-17-2012, 02:09 PM

http://kpr.craigslist.org/mcy/3211602583.html

Funny, one turned up here this morning also.

TheGammaGhost · 08-17-2012, 03:23 PM

Quote:

Originally Posted by FastDoc

http://kpr.craigslist.org/mcy/3211602583.html

Funny, one turned up here this morning also.

Nice, if that was near me i'd be temped to buy it, just to have fun with.

TheGammaGhost · 08-17-2012, 03:24 PM

Cleaned up my work area, Got all my sockets and wrenches organised and back in the case...

Yeah removing the gas tank was really easy actually, One bolt, and then it slid out. Feeling real good about this.

Ill start a new thread pretty soon here, once i get deeper into it, Next is to remove the carb.

FastDoc · 08-17-2012, 04:07 PM

Remove the carb, exhaust, chain, and all but one or two mount bolts. leave those and the wiring attached until the last minute so you don't forget where what goes...

Pics are good for the forum and will also help you remmeber things so take many at each phase. It's like a trail of breadcrumbs to find your way back.

Find help to remove and replace the engine. It weighs about 75 lbs and is a little unwieldy.

TheGammaGhost · 08-17-2012, 05:10 PM

Quote:

Originally Posted by FastDoc

Remove the carb, exhaust, chain, and all but one or two mount bolts. leave those and the wiring attached until the last minute so you don't forget where what goes...

Pics are good for the forum and will also help you remmeber things so take many at each phase. It's like a trail of breadcrumbs to find your way back.

Find help to remove and replace the engine. It weighs about 75 lbs and is a little unwieldy.

Yeah before i did anything, I took a BUNCH, of pictures of how all the cables go and everything was set up. and ill continue to keep taking them as i go on.

As for removing the carb, how do i remove the cable that goes from the throttle to the top of the carb? should i just pull it out? Want to be certain before i do anything.

Yeah ill have my bro help me with the weight of the engine.

Thanks again guys ill keep the questions coming as they pop up.

FastDoc · 08-17-2012, 05:17 PM

Unscrew the cap and the cable will pull out easily with the slide attached. If you need to change the slide to the one that comes on the new engine/carb removal of the cable will be self evident on inspection of the slide.

TheGammaGhost · 08-17-2012, 05:42 PM

Okay i unscrewed the cap, and pulled it out a bit (the cap and cable), it had like a spring, and then a plastic piece at the bottom? do i take all of that stuff out? i put it back in without fully removing it, i didn't want to mess it up.

it looked similar to this one

FastDoc · 08-17-2012, 05:52 PM

Just pull it out straight and gentle. Nothing will fly off.

When you replace it take not of a small locating pin in the carb bore that locates the slide in a particular configuation. This needs to be lined up when you put it back together. 8)

TheGammaGhost · 08-17-2012, 06:25 PM

Done, you explained it perfectly

. Once i removed it i knew exactly what you meant about the locating pin.

everything is off and ready to go, wasnt really hard at all!

Is it going to be difficult to maneuver the engine out? i think i see how it will come out, but just wondering if anyone had any problems.

Thanks for the guidance, seriously! You especially fast doc, you rule man.

FastDoc · 08-17-2012, 06:35 PM

One trick to making the engine easier to remove and replace is to lay something soft on the floor and lay the bike on it's side. Lift/wiggle the engine out from that position.

IIRC with these bikes it's best to lay the bike on it's left side and remove/replace the motor from the right, but YMMV. :wink:

08-17-2012, 12:55 PM	#31
TheGammaGhost Join Date: Jan 2012 Location: Wisconsin, USA Posts: 386	okay cool, i did a few more measurements of where the bolts are at, and it looks like it will fit. Hope i don't have to remove the gas tank. __________________ 2021 Boom Vader Gen 2 BD125-10 Current 2011 DRZ400S Current 2006 LIFANIZED ROKETA DB-06 200cc Sold 2008 Ninja 250R Sold 1984 Honda aero 125 Sold 1980 Honda CM400T Sold
	0

08-17-2012, 01:06 PM	#32
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	You will have to remove it but its simple. What is your concern? __________________ Happy to serve.
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08-17-2012, 01:20 PM	#33
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Nice score on the parts bike, Gamma! You will need to remove the exhaust header, carburetor, clutch cable, throttle cable, drive chain, fuel tank, et cetera, before you can remove the engine. All of this is not difficult. When you are ready to begin your engine switch, please start a new thread, and take lots of photographs. We will help you when you have questions, and your project will be a wonderful resource of information for others in the future. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

08-17-2012, 01:56 PM	#34
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Good score on a parts bike. Engine swap is not too bad. Should take an afternoon to get it done. __________________ You meet the nicest people on a Honda Clone.
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08-17-2012, 02:09 PM	#36
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	http://kpr.craigslist.org/mcy/3211602583.html Funny, one turned up here this morning also. __________________ Happy to serve.
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08-17-2012, 03:24 PM	#38
TheGammaGhost Join Date: Jan 2012 Location: Wisconsin, USA Posts: 386	Cleaned up my work area, Got all my sockets and wrenches organised and back in the case... Yeah removing the gas tank was really easy actually, One bolt, and then it slid out. Feeling real good about this. Ill start a new thread pretty soon here, once i get deeper into it, Next is to remove the carb. __________________ 2021 Boom Vader Gen 2 BD125-10 Current 2011 DRZ400S Current 2006 LIFANIZED ROKETA DB-06 200cc Sold 2008 Ninja 250R Sold 1984 Honda aero 125 Sold 1980 Honda CM400T Sold
	0

08-17-2012, 04:07 PM	#39
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Remove the carb, exhaust, chain, and all but one or two mount bolts. leave those and the wiring attached until the last minute so you don't forget where what goes... Pics are good for the forum and will also help you remmeber things so take many at each phase. It's like a trail of breadcrumbs to find your way back. Find help to remove and replace the engine. It weighs about 75 lbs and is a little unwieldy. __________________ Happy to serve.
	0

08-17-2012, 05:17 PM	#41
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Unscrew the cap and the cable will pull out easily with the slide attached. If you need to change the slide to the one that comes on the new engine/carb removal of the cable will be self evident on inspection of the slide. __________________ Happy to serve.
	0

08-17-2012, 05:42 PM	#42
TheGammaGhost Join Date: Jan 2012 Location: Wisconsin, USA Posts: 386	Okay i unscrewed the cap, and pulled it out a bit (the cap and cable), it had like a spring, and then a plastic piece at the bottom? do i take all of that stuff out? i put it back in without fully removing it, i didn't want to mess it up. it looked similar to this one __________________ 2021 Boom Vader Gen 2 BD125-10 Current 2011 DRZ400S Current 2006 LIFANIZED ROKETA DB-06 200cc Sold 2008 Ninja 250R Sold 1984 Honda aero 125 Sold 1980 Honda CM400T Sold
	0

08-17-2012, 05:52 PM	#43
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Just pull it out straight and gentle. Nothing will fly off. When you replace it take not of a small locating pin in the carb bore that locates the slide in a particular configuation. This needs to be lined up when you put it back together. 8) __________________ Happy to serve.
	0

08-17-2012, 06:25 PM	#44
TheGammaGhost Join Date: Jan 2012 Location: Wisconsin, USA Posts: 386	Done, you explained it perfectly . Once i removed it i knew exactly what you meant about the locating pin. everything is off and ready to go, wasnt really hard at all! Is it going to be difficult to maneuver the engine out? i think i see how it will come out, but just wondering if anyone had any problems. Thanks for the guidance, seriously! You especially fast doc, you rule man. __________________ 2021 Boom Vader Gen 2 BD125-10 Current 2011 DRZ400S Current 2006 LIFANIZED ROKETA DB-06 200cc Sold 2008 Ninja 250R Sold 1984 Honda aero 125 Sold 1980 Honda CM400T Sold
	0

08-17-2012, 06:35 PM	#45
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	One trick to making the engine easier to remove and replace is to lay something soft on the floor and lay the bike on it's side. Lift/wiggle the engine out from that position. IIRC with these bikes it's best to lay the bike on it's left side and remove/replace the motor from the right, but YMMV. :wink: __________________ Happy to serve.
	0