Please help......787 rebuild

[B41ade]

Hi guys.......
I'm a total 2 stroke newb taking on a total rebuild of a 1997 xp.
I picked up a 7 year dead xp with a replacement engine never fitted. After yanking the heads and splitting the cases it was apparent they forgot to remove all traces of water , needless to say a full crank , balance shaft and rotary shaft rebuild was much needed.
Long story short , the bits will be back at the end of the week and the rebuild starts......

The question I have is could anyone spare me a little time and list the biggest do's and dont's
when it comes to a 787 (white) engine rebuild. I'm reasonably confident but can't deny the wealth of knowledge present on the forum.
Any thing that will save me the embarrasment of the motor spinning itself to bits in the first 2 minutes would be eternally appreciated . Many thanks in advance

 

[mikidymac]

Download the service manual for free and follow it step by step. Use either ThreeBond 1211 or 1184 on the cases.

 

[Ckrawiec]

Hi guys.......
I'm a total 2 stroke newb taking on a total rebuild of a 1997 xp.
I picked up a 7 year dead xp with a replacement engine never fitted. After yanking the heads and splitting the cases it was apparent they forgot to remove all traces of water , needless to say a full crank , balance shaft and rotary shaft rebuild was much needed.
Long story short , the bits will be back at the end of the week and the rebuild starts......

The question I have is could anyone spare me a little time and list the biggest do's and dont's
when it comes to a 787 (white) engine rebuild. I'm reasonably confident but can't deny the wealth of knowledge present on the forum.
Any thing that will save me the embarrasment of the motor spinning itself to bits in the first 2 minutes would be eternally appreciated . Many thanks in advance

You say you are a newb, but yet you speak of the pieces and parts like your hands have been dirty before......let the wrenching adventure begin. AS Miki already said...download the full service manual (the bible), read it, follow it, don't shortcut it, assume nothing.....good luck.....you obviously have intestinal fortitude to jump right into it.....

 

[B41ade]

You say you are a newb, but yet you speak of the pieces and parts like your hands have been dirty before......let the wrenching adventure begin. AS Miki already said...download the full service manual (the bible), read it, follow it, don't shortcut it, assume nothing.....good luck.....you obviously have intestinal fortitude to jump right into it.....

 

[kmarts]

When I tore into mine the biggest part for me was finding all the oe spec sealants, thread locker, etc... specifically loctite 518 I had to search for.

Read the manual and get all that stuff and get enough. Manual is wrong for what to use on the case halves, listen to miki. I went through more blue thread lock than I anticipated.

If you even contemplated doing this you're likely mechanically inclined enough... it's not hard if you read and follow the manual.

 

[B41ade]

Thanks , as said I'm a newb to all things 2 stroke. My basic understading is pretty sound but I was just looking for the time served tips and tricks.
I'd never heard of threebond 1211.
Great start me thinks

 

[LikeabossTM]

When I tore into mine the biggest part for me was finding all the oe spec sealants, thread locker, etc... specifically loctite 518 I had to search for.

Read the manual and get all that stuff and get enough. Manual is wrong for what to use on the case halves, listen to miki. I went through more blue thread lock than I anticipated.

If you even contemplated doing this you're likely mechanically inclined enough... it's not hard if you read and follow the manual.

For future reference (especially for Canadian buyers), here's an excellent cross reference for the harder to find Loctite products, generally available from Permatex. For example, I was able to buy the 518 equivalent from Canadian Tire (online shopping/ship to store).

https://www.permatex.com/contact/cross-reference/

 

[mikidymac]

Pretty sure the Permatex equivalent to 518 is 515, I buy it at NAPA Autoparts.

 

[kmarts]

Pretty sure the Permatex equivalent to 518 is 515, I buy it at NAPA Autoparts.

That's where i ended up buying it. At Napa Canada it's a regular stock item in most stores. Canadian Tire was going to take too long to get it. Also Amazon Canada has it too.

 

[mikidymac]

Crazy neighbors to the north....

 

[B41ade]

Does anyone know where to buy all of these in the u.k. or at least their equivalent. I'm having trouble locating them without a month's worth of shipping.
Is there more than one type of manual available , ie service/repair workshop or similar.

 

[etemplet]

I am sure you guys to the north and in Europe have similar products to Loctite available. You need to identify the properties. Any industrial supply company would know their products and you can give them the number so they can cross it over. For instance 515 and 518 are anerobic gasket sealers. As soon as oxygen is removed they harden and seal the surface. 515 used to be called "Gasket Eliminator". 242 thread locker (the blue stuff)is an easily removable thread locker that is designed to cause drag when removing the screw so it it less likely to loosen. The red stuff is 272 and much meaner than 242 and I wouldn't use that stuff. There is also a cylindrical parts retaining compound 609 which you put on a fit that is permanent like a wear ring or loose bearing. It works. 290 Loctite is the green stuff and it hateful to remove unless you have heat. I was taught this many years ago. (note these are old numbers but the new ones still apply)
242 - 30 ft. pounds of pressure to remove
272 - 70 ft. pounds of pressure to remove
292 - 90 ft. pounds of pressure to remove

All that depends o the size of the bolt and cleanliness of the surface prior to the application.