Big end clearance specification

Anyone happen to know the total clearance spec for the big end bearing of a '91 200?

Looks like I'm finally going to be able to do my blown big end, if I can just find that spec.

Dying to ride!

Boot
Melbourne, Oz
85 Virago 1000
91 KDX200 (240SR)
http://www.copperleife.com/craig/bikes/kdx

Fantastic, Dogz! Everything I could ever want.

I had a hell of a time getting the cases apart until I searched the forum and found a few tips on the process. I made my own case splitter tool with a piece of wood and a few bolts. I took some photos and will post them when I finish the film (no digital camera yet, sigh).

A friend swears I can line the crank halves up manually and whack them into alignment by eye. He used to do it all the time on racing two stroke engines, and found them perfect when he tried them in a lathe. I'm going to try.

Anyway, thank heaps for those specs.

Boot
Melbourne, Oz
85 Virago 1000
91 KDX200 (240SR)
http://www.copperleife.com/craig/bikes/kdx

Thanks for the updated spec Andrew.

Lankytim, I can't get those photos done yet, unfortunately, but it's a pretty simple concept. Just a big hunk of wood (very thick chipboard offcut in my case) with holes drilled in it and bolts.

An outer ring of bolt holes in the wood match the alternator cover bolt holes, and an inner one matches the crank shaft end. You buy six very long (100-120mm or so) 6mm bolts and bolt these through the wood into the alternator holes. Another suitable thicker bolt goes through the wood and through a nut on the inner side of the wood to push against the crank. Tighten it up and it works a treat.

I found that the crank was still stuck in the left case after using the above, so I drilled three more holes in the wood to match the left case and did the same thing.

If your main bearings are stuck on the crank, you can use a puller to get them off, or drift them off with a punch poked through the flywheel web holes (which I did). A friend holding a screwdriver and prising the bearing on the opposite side to the punch might help too.

I'll get all this online eventually. Let me know if you need more description, or search on splitting cases and you'll find heaps.

Good luck.

Boot
Melbourne, Oz
85 Virago 1000
91 KDX200 (240SR)
http://www.copperleife.com/craig/bikes/kdx

Don't you hate being away from your tools and workshop? Hope it goes well with the rebuild regardless.

No, I didn't get down to the SBK round at the island unfortunately, but I was there for the moto GP last year, which was wet but fun. It's a great place -- even if it does stick out into the wild weather of Bass Straight.

Cheers,

Boot
Melbourne, Oz
85 Virago 1000
91 KDX200 (240SR)
http://www.copperleife.com/craig/bikes/kdx