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Pegaso 650 Rotax 655 Output Shaft Replacement
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TOPIC: Pegaso 650 Rotax 655 Output Shaft Replacement

Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2171

  • DanH
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How it survived this long, I don't know. Wales trip last year and a blast around Norfolk earlier in April, both could have ended up with an SOS call for recovery.

The problem only became apparent after replacing the chain & sprockets on Saturday, I admit the shaft did look worn, but I was of the mindset that if it worked with the old sprocket, it would work with the new one, how wrong I was.

I managed a whole 2 metres before the bike stopped moving and a metallic whirring noise came from the engine. I instantly knew what the problem was and that the engine had to come out.

So today I decided to clear the bench and wash the bike (I hadn't washed it since the Norfolk blast)....oh and added a little something to it, at 2pm the bike looked like this




By 6.30pm then engine was out and de-greased ready to be stripped.




Here's a couple of images of the the problem I'm faced with






Another showing the new sprocket in place




As you can clearly see, my bike wasn't going anywhere.

After an afternoon of cleaning, bike strip down and engine removal, that will be enough for one day.

The Following day

With the engine out, it was time to start stripping it down. One of the problems was locking it in TDC that required a Aprilia special tool to lock the crankshaft, through a handy access bolt.

You can just make out the cut out section in the crank.


I didn't have the special part to hand, so I had to make one myself


Which did the trick

East Coast asked if the head and barrel can be remove together without separating the two, and the quick answer is yes

The gears are removed from the end of the cams and the chain dropped into the base of the engine, leaving nearly all of the top end untouched.


This is how I have left it tonight, in need of a special tool to hold the inner part of the clutch housing still so I can undo the nut. An old spanner and Mr Grinder to the rescue, me thinks.

Day 3

Well the spanner in the clutch housing did the trick, it locked it off nicely so I could remove the bastid great nut holding the clutch housing in place

I managed to get hold of a fly wheel puller and with the flywheel off the engine came apart.

For GB, a pic showing just how much of the top end was left intact...



This one showing the state of play tonight...



I just hope I can put all the bits back together.


Day 8

Despite it raining all day today, I thought I saw a glimmer of sunshine, my mistake, it was the posties van headlights but he did bring sunshine in the form of ........ an output shaft



Now, since this was out of a BMW F650 I thought I best check to see if the sprocket would fit, and what a stroke of luck, it does



Absolute first class service from Motorworks, I put the order in on 4pm Thursday to be told I may get it by the end of the following week (they had to strip an engine down to get the part) but it turned up 12pm Tuesday, top job

If I had know how quickly the part would turn up I would have put an order in for the gasket set..... so I best stop typing and get on the phone!

Day 20

As you can see, there has been a little break since I posted anything, basically there was nothing to post, I had the sump plug heli-coiled during the week (thanks to Patrick Seager for your prompt service), as the threads had been mushed up by the previous owner, but mostly I have been waiting for parts to turn up...which they did on Friday.

So, today I have installed the new shaft with the rest of the gearbox

Put the casings back together, which went too smoothly for my liking.

By the end of the day I was left with two large bits of engine to put together.

Day 21

Slow start today...and Sunday Roast at my sister meant that I didn't get in the workshop till 3pm...but by 5pm I was at this stage (left it with two bolts holding the engine in)

Day 22

A day of starts and stops made for slow progress and no time for pics. Basically it was a case of remembering in which order the bits went on (fuc messed up a couple of times) but by 8pm it had been fired up and gears tested in the workshop and all panels bolted on ready for the road.

The real test will be tomorrow....

to be continued...
Take the Byway not the Highway
Last Edit: 6 years, 10 months ago by DanH.
The following user(s) said Thank You: Trevor Pastrami, East Coast, Twintec

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2173

Wow Dan,
Well if there is a silver it's got to be that it happened at home.
Re the parts, what's the estimation from Aprilia, on the part, gaskets and seal kit's etc?
If they are out of stock will a BMW shaft fit? (I know because you told me) that the heads are different but don't know about the bottom end.
THE END OF THE ROAD IS THE START OF THE FUN
Last Edit: 6 years, 11 months ago by Trevor Pastrami.

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2174

  • DanH
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You're right there, it would have been a complete fuc bastid if it happened out on the trails.

I asked at Orwell Ipswich for a price for the shaft and it's £115 + V

The BMW F650 also has a Rotax engine, no.654 where as the Pegaso is a 655, the difference being the number of valves, 4 in the BMW and 5 in the Pegaso. I think the bottom end should be the same (hopefully) also the BMW parts might be easier to get hold of and possibly cheaper.

Something I need to look into.
Take the Byway not the Highway
The following user(s) said Thank You: Trevor Pastrami

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2177

  • GB
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DanH wrote:
BMW parts might be easier to get hold of and possibly cheaper.


Wouldn't hold your breathe on the cheaper bit, $286 in the states
Rather be loud than lazy......

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2182

  • Udders
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Try Motorworks for BMW parts. Superb service and very helpful people.
The following user(s) said Thank You: DanH, Trevor Pastrami

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2187

Those short studs/ nuts around the base of the cylinder barrel, will they allow you to remove the top end complete with head i wonder or are there threaded studs passing through the whole lot in addition to these?

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2188

Udders wrote:
Try Motorworks for BMW parts. Superb service and very helpful people.

Good shout Udders,
An excellent firm, with both new and used spares.
THE END OF THE ROAD IS THE START OF THE FUN
Last Edit: 6 years, 11 months ago by Trevor Pastrami.

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2189

  • GB
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I have dealt with Motorworks and Motobins, both really good firms, especially Motorworks
Rather be loud than lazy......

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2190

  • GB
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East Coast wrote:
Those short studs/ nuts around the base of the cylinder barrel, will they allow you to remove the top end complete with head i wonder or are there threaded studs passing through the whole lot in addition to these?


You would still have to do something with the camchain even if they did.
Rather be loud than lazy......

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2193

I guess even if it were the belt style Rotax, while it was stripped down you'd want to re seat the valves etc anyway.
THE END OF THE ROAD IS THE START OF THE FUN

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2194

  • GB
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Just undo everything until you get to what you need is my suggestion
Rather be loud than lazy......

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2196

GB wrote:
Just undo everything until you get to what you need is my suggestion


THE END OF THE ROAD IS THE START OF THE FUN

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2197

Check out this auction on the bay, any use?

www.ebay.co.uk/itm/BMW-F650-GEAR-BOX-GEA...;hash=item2eb89e1580
If you only have one plug, it needs to be a good plug!
July 14 - still true, but now have two plugs!
The following user(s) said Thank You: DanH

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2198

  • DanH
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twntechservices wrote:
Check out this auction on the bay, any use?

www.ebay.co.uk/itm/BMW-F650-GEAR-BOX-GEA...;hash=item2eb89e1580


Nice one Tom that looks just the part I need

I've e-mail the seller to give me an idea of the condition of the output shaft and to send pics, hopefully they will

GB wrote:
Just undo everything until you get to what you need is my suggestion


Noted, actually that's the stage I'm at now...undo everthing
Take the Byway not the Highway
Last Edit: 6 years, 11 months ago by DanH.

Re: Pegaso 650 Rotax 655 Output Shaft Replacement 6 years, 11 months ago #2199

  • GB
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DanH wrote:

GB wrote:
Just undo everything until you get to what you need is my suggestion


Noted, actually that's the stage I'm at now...undo everthing


Glad you have listened young daniel, am I, go far, you will. Hmmmmmm.
Rather be loud than lazy......
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