Subject Index
Lowbrow Triumph 650 Disassembly & Rebuild Videos

The outstanding 13-part Lowbrow video series includes comphrehensive instructions on disassembling, inspecting, and reassembling the Triumph 650 unit engine. Todd's upbeat, humorous delivery provides the crucial info, practical tips, and encouragement you need to get 'er done!
 

Jump To
Part 1  Part 2  Part 3  Part 4  Part 5  Part 6  Part 7  Part 8  Part 9  Part 10  Part 11  Part 12  Part 13 

Part 1. Intro & Remove Rockerboxes

Intro to 650 Engine  (00:00)

Rocker Boxes, Removal  (15:40)

 

Part 2. Disassemble Head/Cylinders/Pistons

Pushrods, Removal  (00:00)

Headbolts, Removal  (00:55)

The Head, Removal  (02:00)

Pushrod Tubes & Seals, Removal  (04:00)

Cylinder Base Nuts, Removal  (05:38)

Cylinders, Removal  (09:20)

Pistons, Removal  (11:12)

Tappets, Remove & Inspect  (13:20)

Tappet Blocks, Removal  (18:00)

Pistons and Bore Inspection  (21:10)

Gudgeon Pin & Piston Removal  (24:40)

Small End Bushings  (27:00)

 

Part 3. Disassemble Primary Chain Case

Remove Primary Chain Case Cover  (00:20)

Remove stator nuts  (03:18)

Remove stator wires and stator  (04:30)

Remove rotor nut and washer  (05:15)

Remove stator studs  (06:32)

Remove Clutch spring adjusting nuts  (07:30) Add note: pressure plate spring 9:27

Remove pressure plate  (10:04)

Inspecting pressure plate springs  (10:21)

Removing clutch plates  (10:42)

Remove clutch rod  (11:58)

Remove mainshaft clutch nut  (12:32)

Locking tool  (12:55) Add note: lock tool, handle vs "barbie stairs" 13:20

Remove rotor  (14:38)

Loosen engine sprocket  (17:00)

Ham-fisted Harry - Remove steipped stud  (18:15)

Clutch center extractor  (19:45) Add note: extractor, not puller 19:45

Remove transmission  (21:20)

Remove chain tensioner   (22:02)

Inspect chain case  (25:29)

Remove trap door screws  (26:08)

Remove trap door  (29:40)

Remove gearbox sprocket nut  (30:45)

Remove gearbox sprocket  (33:05)

Inspect sprocket  (34:05)

 

Part 4. Disassemble Timing Chest and Gearbox

Timing Chest Disassembly  (00:15)

Points  (00:40)

Auto-Advance  (01:50)

Timing Cover  (03:16)

Oil Pump  (06:30)

Crankcase Pinion Nut  (07:44)

Cam Gear Nuts  (09:38)

Intermediate Wheel  (11:58)

Intake Cam Gear/Puller  (12:17)

Exhaust Cam Gear/Puller  (15:02)

Crankcase Pinion Gear/Puller  (17:15)

Gearbox Outer Cover  (20:45)

Kickstarter Pinion and Ratchet  (25:18)

 

Part 5.

Remove Crankcase Fasteners  (00:45)

Draglink Socket, Remove Tach Drive  (05:42)

Crankcase Junction Screws  (12:55)

Splitting the Crankcases  (15:55)

Removing DS Main Bearing Inner Race  (38:24)

 

Part 6. Disassemble Crankshaft/Rods/Rocker Boxes/Head

The Crankshaft, removing DS bearing  (00:00)

The Crankshaft, remove & label con rods  (02:55)

The Crankshaft, inspect journals  (06:45)

Sludge Trap Removal  (09:25)

Disassemble Rocker Boxes  (19:40)

The Head, Inspect & Remove Valves  (26:30)

 

Part 7. Bearings

Vapor Blasting  (00:00)

Cleaning the Cases  (04:30)

ID of Crankshaft & Gearbox Bearings  (07:40)

Checking Camshaft Bushings for Wear  (09:08)

Installing DS Bearing Outer Race  (15:30)

Installing DS Crankshaft Roller Bearing  (19:35)

Installing the TS Crankshaft Ball Bearing  (22:10)

Installing Layshaft) Needle Bearing  (24:40)

Install DS Mainshaft Roller Bearing & Seal  (30:00)

Checking Layshaft Needle Bearing Depth  (31:35)

Installing Mainshaft Oil Seal  (33:05)

Installing Inner Cover Bearings  (35:10)

 

Part 8. Assemble Crankshaft/Rods/Cams & Assemble Cases

Replacing the Sludge Tube Cap  (00:30)

Thoroughly Clean the Journals  (03:17)

Install Connecting Rods  (04:50)

Install DS Roller Bearing (and Assembly Order/Breather Explanation)  (14:50)

Install DS Case Over Crankshaft  (18:25)

Install Exhaust Cams  (20:15)

Apply Sealant to Cases  (22:35)

Drop TS Case onto DS Case  (24:00)

Install Crankcase Bolts  (25:40)

Test Spin Rods & Crank  (31:40)

 

Part 9. Assemble Timing Chest

Assemble Timing Chest  00:00)

Install Intake Camwheel  12:25)

Install Exhaust Camwheel &npsp;14:00)

Install Pinion Gear  16:00)

Install & Torque Nuts  17:30)

Set Cam Timing  18:00)

Install Oil Pump  (23:56)

Timing Cover Oil Seals  (26:40)

Caveat - Plugging Oil Switch -Tapered & Untapered  38:20)

 

Part 10. Install Cylinders/Pistons/Head/Rocker Boxes

Intro to Cylinders  00:00)

Piston Clearance  01:00)

Washing Cylinders  01:50)

Honing Cylinders  02:20)

Wash Cylinders After Hone  03:58)

Painting Cylinders  05:35)

Replace Tappet Blocks  07:05)

Check Threaded Holes  07:20)

Tappet Block Oil Feed Explanation  08:04)

Install Tappets  14:32)

Check Ring Gap  17:48)

Install Inside Wrist Pin Clips  24:32)

Install Rings on Pistons  27:00)

Install Pistons on Rods  29:08)

Install Base Gasket  32:30)

Lube Cam lobes  34:15)

Support Cylinders  34:35)

Stagger Ring End Gaps & Install Ring Compressors  35:42)

Install Cylinder  38:20)

Head Gasket Prep  43:50)

Tappet Block, Pushrod Tube Head & Seal Styles  46:12)

Install Pushrods  53:40)

Install Head Gasket  55:55)

Install Cylinder Head  56:18)

Check Crush Gap  57:10)

Install Headbolts (Snug)  57:48)

Install Spark Plugs  58:48)

Cylinder Head Work (Discussion)  59:35)

Rocker Boxes (Discussion)  1:01:05)

Assemble Rocker Shafts & Thackary Washers  1:02:50)

Rocker Caps  1:13:45)

 

Part 11.

Assemble Gearbox  (00:00)

Assemble outer cover components  (1:50)

Assemble kickstarter quadrant and spring  (11:10)

Inner cover - Assemble inner Quadrant  (13:00)

Inspect camplate  (18:05)

Plunger, holder, and plunger spring  (19:20)

Depress plunger and install camplate  (20:50)

Install high hear  (23:50)

Install sprocket  (25:00)

Sprocket locking tab and securing nut  (26:40)

Torquing the sprocket nut (90lbs)  (27:30)

Trap door seals - old and new  (28:60)

Inspecting gears  (30:20)

Install drain/level plug  (31:10)

Examine shift forks and rollers  (32:50)

Install thrust washer  (35:00)

Setting up camplate in 1st hear for indexing  (36:45)

Install layshaft and layshaft selector fork  (38:00)

Install first two mainshaft gears () and mainshaft selector fork  (39:00)

Install shaft for shift forks  (20:05)

Install last mainshaft gear  (40:55)

Slide in the mainshaft  (41:12)

Put on layshaft low gear  (41:50)

Begin outer cover  (42:40)

Install inner cover and index  (44:00)

Install kickstart components  (45:00)

Inner cover screws and bolt  (46:30)

Install outer cover and check gears  (47:38)

Install oil junction block  (55:00)

Install kickstart shaft with spring in outer cover  (56:45)

Install outer cover  (58:00)

Winding up the kick spring  (1:00:00)

Install outer cover fasteners  (1:00:40)

 

Part 12. Assemble Transmission/Primary Chaincase

The Primary Drive  00:00).

Checking Components for Wear  (00:40)

Clutch Basket  (01:17)

Inspecting Clutch Components  (01:40)

Clutch Shock Absorbers  (03:11)

Engine Breather and DS Crankshaft Oil Seal  (05:15)

DS Crankshaft Oil Seal Orientation  (06:05)

Trap Door Seal  (09:15)

Trap Door Screws, Gasket, Sealant  (12:02)

Alternator Wire Tube  (15:55)

Chain Adjustment Shoe  (16:20)

Transmission Assembly Laid Out  (19:30)

Clutch Assembly, Roller Bearings  (19:55)

Thrust Washer  (22:04)

Clutch Center Cover  (23:38)

Stator Studs  (35:22)

Install Rotor  (38:25)

 

Part 13. Assemble Pushrods/Rockerboxes/Adj Valves/Clutch

Install Pushrods, Rockerboxes. Adjust Valves, Adjust Clutch  00:00)

Install pushrods  01:00)

Setting pushrods to low point  02:20)

Gasket  03:09)

Install rockerbox  04:04)

Install Headbolts  04:36)

Install Rockerbox Studnuts  05:56)

Snug down headbolts  07:17)

Snug rockerbox bolts  08:00)

Snug down studnuts  08:12)

Check pushrod action  08:12)

Lower intake pushrods  10:00)

Install intake pushrods  10:29)

Position intake pushrods  11:11)

Install intake rockerbox  12:48)

Install headbolts  13:30)

To be continued