Complete dirt bike restoration

Carder09 · April 23, 2013

keep the number tags white and why not keep her zuki yellow

Its staying yellow, frame will be matte black, and probably won't have any lettering on it whatsoever, but who knows, I like to customize.

Carder09 · April 28, 2013

So the final matte clear coat was applied yesterday and today I have started assembling the bike together. I have the engine mounted up, the rear swing are and shock, tire, and brake together, and I also have the front forks and tire installed and that it where I have left off. I will do my best to get some pics of the progress up tomorrow.

Carder09 · May 7, 2013

Update: Started the bike twice and the last time I started it it reved to the heavens by itself and the kill switch would not turn it off. Had to almost completely remove the air/fuel screw while also turning off the gas before it stopped. Doesn't start and occasionally backfires so I'm praying I didn't mess the new rings up or score the cylinder walls. I'm going to check everything else before I tear back into the motor. But that's what I'm held up on now besides painting the plastic and completing the smaller assembly of stuff.

NitroCherokee · May 7, 2013

Update: Started the bike twice and the last time I started it it reved to the heavens by itself and the kill switch would not turn it off. Had to almost completely remove the air/fuel screw while also turning off the gas before it stopped. Doesn't start and occasionally backfires so I'm praying I didn't mess the new rings up or score the cylinder walls. I'm going to check everything else before I tear back into the motor. But that's what I'm held up on now besides painting the plastic and completing the smaller assembly of stuff.

Just a dumb question but, why didn't you pull the plug wire off to kill it?

Carder09 · May 7, 2013

How I had my tank temp installed didn't allow the easiest access to the plug. If I would have tried, probably could have grabbed it with some long needle nose

NitroCherokee · May 7, 2013

How I had my tank temp installed didn't allow the easiest access to the plug. If I would have tried, probably could have grabbed it with some long needle nose

I said it was a dumb question

Carder09 · May 7, 2013

Well you got an answer anyhow

Carder09 · May 25, 2013

So, I have just gotten time today to tear back into the bike, the gaskets are all fine and I looked at and removed the piston rings and they are in good condition with no breaks. I am at a loss and not sure what else I can check. I decided to bust into the exhaust valve portion of it and messed up one of the adjustment springs somehow so I now have to wait probably a month before I get that but it was all free since I had enough bandit bucks to pay for shipping and the spring. So as for that, I am going to take the head up to the moto shop to see if they can find anything wrong with the cylinder wall though I see no issues with it at all.

J-man67 · May 28, 2013

Did you measure ring end gap? Thats a biggie. Personally, I would of just rebuilt the motor. I have made that mistake a couple of times...fore-going a top end with hours on it b/c it "felt OK" or had good compression. At least an entire fresh top end with some cylinder measurements. 60 hours is over the normal 40 of today so I would def keep that in mind. Also, take the side cover off and see if the crank shaft has any movement at the flywheel. If it does, main bearing time! One more thing that is often over-looked; linkage bearings. If you have never done them on the bike, just do them as well. They are probably rusty/dust by now. Just some things to look at/keep in mind.

Carder09 · May 28, 2013

Everything measured perfectly within limits of the manual. As for top end, everything g was done, bottom end, I have yet to bust into it and cannot invest in it at the moment but definitely will when I can.

J-man67 · May 28, 2013

Well then you covered your bases. As long as your crank is tight, you should be good to go. Did you clean your carb or re-jet it?

Carder09 · May 29, 2013

Well then you covered your bases. As long as your crank is tight, you should be good to go. Did you clean your carb or re-jet it?

It was re-jetted few years ago by a shop, I recently took it all apart and let it soak in carb cleaner since I though that the carb was the original culprit but it still didn't help even when I adjusted it to manual specs then fine tuning. I might just go ahead and get the cylinder re-plated, not sleeved, and order some new rings and probably gaskets as well just to make sure everything goes accordingly.

J-man67 · May 29, 2013

It was re-jetted few years ago by a shop, I recently took it all apart and let it soak in carb cleaner since I though that the carb was the original culprit but it still didn't help even when I adjusted it to manual specs then fine tuning. I might just go ahead and get the cylinder re-plated, not sleeved, and order some new rings and probably gaskets as well just to make sure everything goes accordingly.

Sounds like a plan to me. Forget if I read this or not, but have you done a compression test?

J-man67 · May 29, 2013

Also, just thinking of what causes erratic idle...crank seals could be something to look at. Leak down test would answer that. Other then that, and since you checked a lot of things, I don't have any more ideas. Wait, one more. Not even sure how much this matters, but exhaust packing? Ok, now that's really it! Good luck man. I recently did a rebuild on my 00 Yz250. Enjoy it man, once you are done and riding it again, it becomes totally worth it!

Carder09 · May 29, 2013

Yeah, compression is or was sitting at 60psi, min is 180 for my bike. Packing has been changed as well and it looks like it isn't blocking anything so I'll see after some other evals.