2008 Brute Force Bottom 'Knock Knock' rebuild

Probably the other question I had too, what service/repair manuals are we using for the brute forces?

There will be no straight conversion kits to take a 650 to a 750 as (we've been told) the 750 jugs won't fit the 650 lower case without machining and the 650 case won't take the 750 crank without a thrust bearing replacement and reset. It's all been done but it isn't cheap. If yours is a 650i it might be cheaper just to fins a complete 750i carbed engine and swap it out complete. It will just bolt into your frame as is.

Thanks for the reply NMKawierider
Sourcing secondhand engines or parts in Aus for these bikes is hard.

How big of a job is a full rebuild for someone with half an idea and a shed full of tools?

hunterschamps said:

Thanks for the reply NMKawierider
Sourcing secondhand engines or parts in Aus for these bikes is hard.

How big of a job is a full rebuild for someone with half an idea and a shed full of tools?

Click to expand...

Well...if the shed had everything you needed to not only to do all of the R&R but to check all the parts specs and do it cleanly, and you don't mind buying or borrowing the special tools needed and has a machine shop close by for the machine work (Boring,decking, rod reconditioning, valve job...ect)...and of course a full shop manual and access to parts...sure, anything's possible.

NMKawierider said:

Well...if the shed had everything you needed to not only to do all of the R&R but to check all the parts specs and do it cleanly, and you don't mind buying or borrowing the special tools needed and has a machine shop close by for the machine work (Boring,decking, rod reconditioning, valve job...ect)...and of course a full shop manual and access to parts...sure, anything's possible.

Click to expand...

Any suggestions on a manual to purchase?
Machine shop no issue, ive got a flywheel puller and primary removal tool.
Will be purchasing a full rebuild kit for this, rather than using older components - the bike has 20,000kms on it.

hunterschamps said:

Any suggestions on a manual to purchase?
Machine shop no issue, ive got a flywheel puller and primary removal tool.
Will be purchasing a full rebuild kit for this, rather than using older components - the bike has 20,000kms on it.

Click to expand...

Is this an 2008 SRA or IRS 650? And with 20,000kms are you sure the frame isn't showing fatigued areas?

NMKawierider said:

Is this an 2008 SRA or IRS 650? And with 20,000kms are you sure the frame isn't showing fatigued areas?

Click to expand...

Frame is fine, and it'd be the least of my worries if it was fatigued.
It was used as a spray rig all its life. Done 2500hrs in those 20,000km, so averaged around 8k an hour since new..