R65 Camshaft Replacement

[Danie]

I do not have any previous experience on boxer engines, and would appreciate information regarding the replacement of a camshaft:

1. I have removed the front engine cover, but I do not have the correct screw press to remove the altenator rotor. Is there any other way to remove the rotor, apart from using a screw press ?
 If not, I would really appreciate a pic of a screw press which can be used for this purpose.

2. I also do not have the correct extractor tool to remove the timing cover. Can the timing cover be removed without an extractor tool?

3. I suppose the camshaft can be removed just by unscrewing the camshaft flanched bearing fastening screws ? (obviously the chain tentioner, chain, push rods, and lifters will have to be removed first)

Sorry about the stupid questions, - I've only got a R60/6  75/6  90/6  90/S Repair manual, and I am trying to find as many information as possible, before I go ahead.

Many Thanks
Danie

[MrRiden]

I would really appreciate a pic of a screw press which can be used for this purpose.

available on line at http://www.northwoodsairheads.com/Tools.html

[Danie]

Thanks MrRiden

If I can't find one locally, I will try and make one on the lathe.

Danie

[trolle]

Hi Danie

I use a short metal pin with a slightly smaller diameter than the alternator screw and which is so short that it does not cover the outermost thread in the alternator screw whole. (There is a thread in the crankshaft end and a thread in the alternator whole).To dismantle the alternator I place the pin in the screw whole and use the screw for the alternator to press the alternator out.

greetings from a norht with varying cloud cover and tolerable driving conditions (dry and 45F)

trolle

[Danie]

Thank you very much Trolle - your advice will save a lot of time.

Do you perhaps know whether the timing cover can be removed without an extracting tool ?

I will start working on the bike tomorrow evening.

Regards

Danie

[trolle]

As far as I remember there will be no problems in removing the timing cover once you have dismantled the alternator, the rectifier (diodeboard) and the "beancan".

greetings from a quiet and dark north

trolle

[airhead]

Thank you very much Trolle - your advice will save a lot of time.

Do you perhaps know whether the timing cover can be removed without an extracting tool ?

Danie

Some just slide off without too much trouble, others sometimes need a little heat on the crank bearing boss (where the alternator sits) before it will come off. Putting back on you will most likely have to heat the boss again to allow the bearing to slide in and let the timing chest bottom out on the case.
Don't forget the two small gasket/washers on the top chest screws.

Bill......................;-)

[airhead]

***CAUTION****

Just read the post from Trolle about using a short metal pin. Be very careful if you go this route that you use a pin of hardened steel, not mild steel.
It certainly wouldn't be my preferred method even then, the turned down screw is the preferred tool. If that pin breaks, or even bends, in the hole, it will be a devil of a job getting it out, especially if a mild steel one bends and gets jammed between the hole base and threads.
Hopefully the rotor shouldn't be jammed on so tight it would ever get to that stage (most just pop off without too much fuss), but it has been known.

Bill.......................;-)

[Danie]

Thanks for the advice.

Hopefully a  6 mm stainless steel pin will be hard enough  to do the trick.

Will let you know whether it worked.

Regards.

Danie.

[Danie]

Again, thanks Trolle - the stainless steel pin (6mm x 45mm) worked perfectly - and the rotor came loose quite easy.

For what it's worth - I have just polished the pin ends with a flapsander, to make the contact areas as smooth as possible - maybe there is no need to do  this at all.

The timing cover seems to be a complete different story ......I can't get it loose, and my gas bottle (acythelene) is empty - so I will probably have to wait untill this coming weekend to heat the crank bearing boss ........

[Bob_Roller]

The timing cover does not have any bearings, just the front main seal.

Make sure all of the fasteners are removed, and take a piece of wood and a hammer, and a few moderate hits should loosen it up.

From what vague memory I have of removing the timing cover, there were one or two fasteners, I think it was one or two 'phillips head /cross point' screws that were a bit 'hidden', so make sure all of them are removed before applying 'impact' force.

[trolle]

That is right, there are more screws, than you expect, and as the cover sits on a gasket it may stick a little, so as Bob recommends, a few taps with a rubber hammer or a hammer and a piece of wood should do the trick.

greetings from a windy and cold north (30F)

trolle

[airhead]

The timing cover does not have any bearings, just the front main seal.

Make sure all of the fasteners are removed, and take a piece of wood and a hammer, and a few moderate hits should loosen it up.

From what vague memory I have of removing the timing cover, there were one or two fasteners, I think it was one or two 'phillips head /cross point' screws that were a bit 'hidden', so make sure all of them are removed before applying 'impact' force.

Bob, the timing chest has a bearing sitting in it, if you're s didn't then it's been left of!!! It sits on the front of the crank just behind the alternator and main seal. The bearing boss sometimes needs to be heated to release its grip before the chest will come off, and likewise go home fully.

Bill.................;-)

[Bob_Roller]

I removed the cover 10 years ago, and had no problem removing it, I know I replaced the front seal, probably never noticed the bearing on the crankshaft.

I'm sure if it wasn't there, I doubt I would have 80,000 miles on it without problems !!!!

[Semper Gumby]

There is a bearing under the timing cover under the seal.  I was told to heat the cover to get the bearing out but mine while snug wasn't tight enough that I couldn't remove it by hand.  Perhaps you will be as lucky as I?