[Grand Designs] project - my ETZ 250

[Puffs]

Removed

[dirtsurfer]

New clutch puller arrived today. It looks substantial


I was able to find it locally , nearly everything else I require comes from the other end of the world.

[dirtsurfer]

Looks like you have lots of work ahead of you. I am in Sydney and am riding an 85 model which I have owned since new. I might be able to help if you have any questions. There are not many of these in Australia. Bruce

Thanks Bruce.
I'm the bloke that Mike mentioned in his email over the week end. I'll keep in touch

[Puffs]

OK, I see - dirtsurfer.

That puller indeed looks very heavy duty, certainly considering both are M24x1.5 on the business end. Hope it pulls it off.

[dirtsurfer]

Some parts arrived today packed like this:

Seriously!

Anyway I hope to get to work with the pullers this week - end

[breakwellmz]

Do think the box wasn`t big enough?

[Andy_C]

Do think the box wasn`t big enough?

Purchased through Amazon by any chance? - they have a reputation for overpackaging.

[dirtsurfer]

My issues with the packing were
that the bearings were not taped or bagged together just left to float freely around inside the parcel. Two bearings are unboxed and one of those with no individual packaging at all.
This is suboptimal!
The parts came from a popular MZ parts supplier in Germany.

[Puffs]

A discussion on a US forum of the packaging of an Australian's order of Chinese-made bearings in Germany...

[breakwellmz]

A discussion on a US forum of the packaging of an Australian's order of Chinese-made bearings in Germany...

Read by me in the UK and commented on by you in Belgium.

[dirtsurfer]

Gotcha! little bugger



The handle started to bend on the puller I waited for. I wound up using an 8.8 bolt that I found in the hardware store while I was looking for something else, When I heard the crack I half expected to see a broken bolt.

and......

You too Kupplung!



Same thing I thought something must have broke; but just the bind

Next , I'll start on the crankcase bolts, some of those little suckers may give me trouble but I'm feeling confident after getting the clutch and rotor off.



The crancases had been soaking in diesel for a while which I believed helped , plus using fair dinkum tools

[Puffs]

Good on you!

Yes, that seal looks like it needs replacing...
And your diesel might work similar to WD40, and is likely to have helped.

Be careful with the crankcase bolts: avoid damaging their heads & do not let the screwdriver slip out. (--> Allen bolts?)

[dirtsurfer]

I move forward in small increments. I broke a flat blade insert on my impact driver trying to one of the many awkwardly placed crankcase screws. I got a long stemmed screwdriver so I could exert maximum man power to get those little screws out . They all put up resistance but eventually I got all of the little buggers, using the right tool again.
This evening I made up a reasonable facsimile of a crankcase splitter. The bolt I used to remove the rotor came in a packet of two with 2 X M10 nuts. I had some 20mm X 20mm steel laying around and the nuts only just slide inside the 20 X 20 but no room to turn. So I drilled some holes for the M10 and M6 bolts in the right places (first time ever) and slid the nuts into the steel. It all looks about right and not as heavy duty as this but hopefully it should be strong enough, but I have to get another M10 bolt before I can test it . The bolt I used on the rotor has a damaged thread, so does ever other bolt I used on that rotor

[dirtsurfer]

Success!


Tool not strong enough though

[Puffs]

Cheers!

And from here on it's building, which is nicer.