removing engine verses top and hints

[pasam]

Hi,
I need help in suggestions on how to remove the engine or just the engine top to remove debris from the top of the piston in a voyager 1200, 2003. Any suggestions on what all needs to be removed will be appreciated.


Also this subject may have been covered before but, the site for some reason does not allow me to use the search feature.

Thanks, Sam in central PA.

[cushman eagle]

I do not know what you need to remove from the top of the piston
But a couple tricks I have learned working in our farm equipment repair shop:
1-Fasten a small piece of tubing, that will fit in the spark plug hole,to an air compressor nozzle.Bend the tube to enter the plug hole,insert the tube and try to blow out the dirt,swishing it around to get it all.
2-I will also at times,fasten that same tube to my shop vac, with an assortment of hoses and fittings,trying to vacuum them out!
I have been fairly successful in cleaning debris put of cylinders,etc,without disassembly

[ekap1200]

More info. what could possiblly have gotten into the jugs. Did a rodent chew thru the air filter, or did removel of spark plugs foul things up. We sure want to know why anyone would want to pull the engine when spring is just around the corner. And what and how did debris get in there.

[cranky]

.. thanks for that ? ... it was kinda drivin' me nuts too..... all ears???? GBG

[ekap1200]

.. thanks for that ? ... it was kinda drivin' me nuts too..... all ears???? GBG

This is for all the newer bike owners that winter their bikes in a shed....... make damn sure before you hit the starter, that no rodents have made a home anywhere in the air intake.....And that your battery is at 100% charge , not just a bit on the charger , but surely at 100% based on what type of battery you have and the using the proper method of chargeing.

[pasam]

hi,
He lost a piece of the end of a plug wire in #2 cylinder when he pulled the plug. He screwed up by not blowing the area out well enough. The piece appears to be plastic or bake-lite from the end of the plug wire. it was apparently broken off beforehand, about 1/4 inch wide in a half moon shape. We have already tried all kinds of vacuum hoses, but no luck, even a sticky stick arrangement. We will make another good try before pulling the motor. We are fearful with blowing air in not knowing the valve position. A good lesson to make sure nothing is down beside the plug before pulling it.

Sam in central PA

[cranky]

... ouch.. and thanks for the update!!!!

[Thadbaker86voyager]

It is amazing what can hide in those spark plug wells!! Have found all kinds of road debris. But anything that was ever dropped ends up there too! My favorite is electrical fuses!! Be sure the drain holes are open!!

[Barry]

With some creative thinking, you should be able ensure the exhaust valve is open. Then apply air to dislodge.

[Mr Jensee]

Shark has a tool with a small tubing part that you could use to insert into the piston hole and vacuum out the debris. It only works with their Rocket models.

[ekap1200]

Surely worth the effort and at least another hour or so fishing. Try putting the piston at the bottom of stroke and fishing with something long and somewhat flexable with some HEAVY grease on the end of it. Happy fishing, This could be an expensive fishing trip and a lesson one won't forget. This is why I tell people, if you don't own an air compressor, don't even bother with changing the plugs more harm will come from it.....
Gene

[Barry]

Have you tried using a small grabber tool similar to this one?

https://www.lowes.com/pd/Kobalt-Flex-Cl ... 8f9cb332e2

[cushman eagle]

Yes,Barry,That is another tool I rarely use,but very happy I have on hand when I need it
I would guess mine is 25+ years old,but has paid itself off many times

[ekap1200]

I got one more trick up my sleeve. get your piston at bdc and shoot some heavy grease down in the jug. Now using thin #22 wire feed down into the jug about a foot or so. The thin wire will allow for a larger piece be passed thru the plug hole. pull it up slow and easy as if your crabbin with a line and a piece of chicken on it.....

[ekap1200]

Well we all want to know how you are doing on your fishng for the broken spark plug cap. It seems so common to find a broken cap on #2 , and it should not be. There have been numerous posts for the EASY way to get that plug wire out of the way in this AVA forum. But I will post it again for the newbies. remove the two philips head screws from the throttle splitter and snake the plug wire out from underneath . Now you can lift the wire out of the way.

We have given you enough advice now to get this out of the jug. If it fit down there it can be fished out. NOW if there was alot of sand and small gravel , well you may be in trouble.

keep at it, It will not cost anything to keep at it at this point.