how hard is it to replace 61x cases

[Fro Diesel]

So i was trying to get a bolt that had broken off out of the intake. Broke off the easyout flush with the top. I took it to a guy to see if he can fix it, but how hard is it to throw on a new set of cases?

I am trying to get this done before i leave for daytona. A friend let me borrow his ski, and we were trying to put on a wetjet intake when we fubared it all up.

What all do i need to swap cases? Besides exhaust, base, and intake gaskets?

 

[ADDict]

Seals. Get a base gaskets, intake/exhaust, head gasket or 0-rings, and front and rear seals. Probably a gasket for the timing cover. Do you have cases? You can usually find them quick and cheap. Good luck bro! Get that chit ready!
As for easy, it is.. Just make sure you get the manual out and get the torque specs for the case/cylinder/head bolts etc. Shouldn't take ya too long, more cleaning and prepping than anything. Get some yamabond.

 

[Matt_E]

You will need to remove the motor from the hull (obviously).
Remove intake stuff
There is no reason to take the exhaust manifold off.
Remove starter, flywheel, stator
Remove cylinder head and cylinder
Remove pistons
Split the cases

Reverse the process for new cases. There's actually a thread on 701 assembly stickied in the Tech FAQ

 

[ADDict]

You will need to remove the motor from the hull (obviously).
Remove intake stuff
There is no reason to take the exhaust manifold off.
Remove starter, flywheel, stator
Remove cylinder head and cylinder
Remove pistons
Split the cases

Reverse the process for new cases. There's actually a thread on 701 assembly stickied in the Tech FAQ

Good point, lol.

 

[QuickMick]

Just dont reuse your old seals, or at least I wouldnt reuse old seals. I would go with OEM seals.

also put your pistons back in the same cylinders they came out of.

 

[The Penguin]

while you got the starter out - replace the o-ring seal

 

[Matt_E]

while you got the starter out - replace the o-ring seal

Why? :dunno:
I've never had one go bad in almost six years.

 

[accbr]

You don't need to remove the cylinder head either. Just take the cylinder off with the head still attached. Check your squish after you reinstall the cylinder.

 

[madscientist]

i have at least 1 top case here as well as a couple of bottoms.

 

[LIVE2RIDE Powersports]

I have matching sets for 75 shipped

 

[Fro Diesel]

pm's replied. I have to wait to hear back from this guy around the corner from my shop who has been my go-to guy for welding. He runs a super small cycle shop a stones throw away from work. Otherwise i'll be hitting everyone up for stuff tonight!

THanks for all the responses.

 

[GDFL]

Why? :dunno:
I've never had one go bad in almost six years.

I just had a starter go bad. It was in 10x better condition than my backup starter, but the O-ring got some flat spots in it (somehow) and let enough water in to rust the needle bearing and make the brushes stick with rust around their holders. Luckily, there wasn't enough water to screw up the stator or flywheel.

 

[Matt_E]

I'm all for inspecting it, but flat-out replacing it no matter what?
I guess they're cheap.

FWIW, put some 1211 on that.

 

[The Penguin]

I'm all for inspecting it, but flat-out replacing it no matter what?
I guess they're cheap.

FWIW, put some 1211 on that.

yup - they are cheap and if you've got the starter out anyway...

 

[sjetrider]

just drill it through and through bolt it for now!

 

[smoofers]

just drill it through and through bolt it for now!

He won't be able to drill through the easy out that is broken off in the bolt. Easy outs are super hard, drill bit killers.

 

[chriselmore_1]

i hate easy outs sometimes they work great. and sometines they break.. if the bolt is sticking up enough ill jb weld a tight fitting socket on to the bolt then crank it off with a ratchet and breaker bar. a little heat wont hurt either. if you get new cases pm me and ill give you the torque specs from my manual

 

[-XXX-]

He won't be able to drill through the easy out that is broken off in the bolt. Easy outs are super hard, drill bit killers.

This is what I use.

Find a Machine Shop near by that has one.
Alot of extra work going the other route.
Good Luck!

http://www.electroarc.com/?gclid=CP27qI21kJ8CFWkN5QodjQxj7w

 

[ADDict]

This is what I use.

Find a Machine Shop near by that has one.
Alot of extra work going the other route.
Good Luck!

http://www.electroarc.com/?gclid=CP27qI21kJ8CFWkN5QodjQxj7w

Damn, that is great!

 

[Fro Diesel]

well guys,

Had to weld a stud to the hole i made closest to the gas tank and jug. Then i modified the wet jet intake so i could tilt the intake mani and reed cages into the ski. All new stainless allenhead hardware w lock washers. Jetmaniac gasket (thanks for speedy delivery as always Chris!) and it seats very nicely.

Fired right up after cutting back the coil wires. Was pouring gas down teh carb. Couldn't get it to fire on it own. Kept getting worse every attempt anything i did, change lines run it direct, new filter.

Finally got pissed and pulled the carb to find enough junk clogging it to fill your parent's garage. Should be good to go. Superjetdave is cleaning the S.O.B. right now.

pics eventually. see you in less than a week my Addicted friends