TRX250R.ORG
General => Projects => Topic started by: Jimbo45 on February 18, 2015, 07:35:48 PM
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This thread was posted on another forum, but thought I would share here as well! No need to answer any questions through post #21, since it was just a copy and paste up until then. :sentimental:
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Hey guys! A little backround, I had a ragged out '87 250R when I was 18, back in 1995. I had grown up on 3 wheelers, and always lusted over my friends' 250R's (the '88 version especially), as a younger rider. I traded a junky Mustang for that old '87, and loved every minute. It was white and blue. My best bud also bought an '86, that was red and white, and we raced those things all over the countryside! Good times. I went into the service, and my 250R was sold while I was gone. :02.47-tranquillity:
As I aged, I got into dirtbikes and had a CRF450R and then a CRF250R, and a LTZ400 in there somewhere. Having kids, and no time to ride, and no need for broken bones, I traded my last remaining bike, the CRF250R, in on a Polaris RZR, to hunt with. I figured a 250R was a thing of the past, and I would never see one again. Man, how I recall, and miss that 2 stroke zing and smell.
Well, as luck would have it, last week, a buddy mentioned he wanted to get rid of a quad that needed work. It was a 250R! We negotiated a trade, and he showed up with an awesome example of an '86 250R!!!!!!!!!!!!!!!!!!!!!
8 years ago, the engine was torn down and rebuilt, and that frame powder coated, and new plastics installed. He rode it a few years, and an airbox issue grounded it for the time being, and he got busy with life, and never got around to fixing it. It sat for several years, until now.
It doesn't run yet, but I just acquired a nice OEM airbox and an airbox ring today, and will get the airfilter tomorrow. I know that I will likely need to replace both brake master cylinders, and some other parts, and the rear sprocket seems to have some play on the axle. Will probably do a topend too. I wished he had done the gussets before powder coating, but I don't see any cracks yet, so fingers crossed. First off, I need to remove the carb, a Mikuni TMX (I think its a 36 or 38, haven't measured yet), and clean it out, and inspect the top end while the carb is off. Then, put on the new airbox, and see how it runs! I can't wait!!!!!!!!!!!!!!!!!!! I really wish it had the red '88 plastics, those are my favorite! I may look into doing that, and installing the front and rear lights again. I always wanted a stock looking '88!
Anyway, that is my intro, and I will post updates as I go. Here are some pics from the day I brought it home.
(http://img.photobucket.com/albums/v163/jimbo45/2014-12-12%2017.35.20_zpsbyyo4eag.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/2014-12-12%2017.33.58_zps5zy6rysn.jpg)
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^^^^^ That's how I got it a couple months ago. Buddy said it sat for a few years, after he quit riding it due to an airbox issue. He had done a lot of work to it when he got it. He sent me a bunch of pics of it down to the frame before powder, and with the engine split.
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Then progress slowed a few weeks, while I got this for $600 ( had to do a little work to it though) for my boy, for Christmas!!!!!!!!!!!!!!!!
(http://img.photobucket.com/albums/v163/jimbo45/20141215_132847_zps5x48lqyv.jpg)
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Tonight, I had a few hours to work on the 250R. I installed the new airbox and filter and checked out the carb, and it looked reasonably clean in the bore, but there was nasty smelling black gas in the bowl. After a super asinine gas leak from where the fuel strainer bolts to the bottom of the tank (and dumping a bunch of fuel on my garage floor), I got that fixed by adding an additional oring I happened to have, I noticed the gas shut off valve also leaks bad, when in the run and res positions. Dang. But, after hooking everything up, and putting fresh oil in it, I filled the carb bowl, then shut off the valve to prevent another huge puddle. After about a dozen kicks SHE CAME TO LIFE!!!!!!!!!!!!!!!!!!! It ran like crap and was hard to keep going, but it RAN! Since it was 11PM, I decided not to try again, and let it die after about 30 seconds. IT LIVES!!!!!!
So, I have determined I need to fix the gas shut off valve...can you rebuild those? Where do I find a kit? Also, I will need to rebuild the carb, since I noticed all the gunk coming out of the bowl when I drained it. It is a Mikuni TMX 36mm. Where do I find a kit? Where do I find a jetting guide, to get me close, for a starting point, with my setup?
This is so exciting, I can't wait to get it ironed out, and RIDE IT!
Well crap. I spent all afternoon removing the carb and disassembling it, and cleaning it out the best I could. After putting it back together, it ran a few times, briefly, but would climb in RPM, and then sputter out. After a few times like this, it got to where it wouldn't start. I considered rebuilding the carb, but I am thinking I just need to buy a new carb, that might work better. Strangely, I searched for a Mikuni TMX 36mm, and several pop up and are available, but look nothing like mine!? Mine is marked "TMX" on the slide housing, and I measured it at 36.01mm. What the heck? The ones I see online, have a screw on panel, on one side of the slide housing, and generally look different. Mine has no screws on the slide housing. Can someone recommend a low cost reliable new carb that I can purchase, that will work with my stock airbox boot? I am not too concerned with ultra high power, just something that will run clean with my setup. Stock stroke, mild porting, Curtis Sparks MX pipe, uni airfilter in stock airbox, with an Outerwears cover on the airbox. I can't dump a lot of money on this bike, but I need it to run!!!!!!!! Off to the carb/jetting forum............
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This is exactly like my carb.....
(http://img.photobucket.com/albums/v163/jimbo45/MikuniTMX36mm_B0059-5_zps91c01072.jpg)
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No pics to add, but I have made some progress. Some of you may have seen my carb post in the fuel/air section. Long story short, I ended up ordering a new Kiehin PWK 38 A/S along with a cable this morning, to start with a better carb. Besides, I wanted to treat myself to an early Christmas present. I was sure that old TMX carb was beyond repair!
So, coming home from work, as I walked through the garage and near the R, I recalled a large nut on the floor from last night. Looking it over, and looking at all the suspension pieces, they were all GTG, so where did it go? Then I saw it.....one of the cylinder base nuts was missing. DOH!!!!!!!! I looked at the other three, and they were coming loose too. There was a good 1/16" gap at the base of the cyl, but the gasket looked ok. Oh wow, am I stupid. I had checked over all of the suspension fasteners, as the previous owner suggested, and the head nuts, but never thought to check the base nuts. Dang. THERE WAS MY AIR LEAK!
So, after supper, I went out, and torqued the cylinder down to 34 ft pounds, and checked every fastener on the engine. Three kicks on choke and the beast came to life, and after a few seconds I turned off the choke and she purred like a kitten. Face palm. YAY!!!!!!!!!!!!! IT WORKS!!!!!!!!!!
The bad news, I have a badass carb on the way that I really didn't need. LOL! Just like the gas shut off valve that dumped gas everywhere no matter how I turned it, and now that I ordered a rebuild kit for that, it hasn't dripped a drop. LOL! I need to name this 250R....something ornery.......
No, its really ok, I am sure the PWK will be a much better carb, and easier to dial in just right.
So, whats a nice, used, clean, Honda CR125 OEM style Mikuni TMX36 worth? :05.18-flustered:
Now, when I get a few hours to add brake fluid and attempt to bleed brakes, and continue checking all the fasteners. grease the rear linkage, and change the oil once more after some running time, I may be ready to ride this thing a bit with my boy, and do some fine tuning, when he gets his 250ex for Christmas! Oh and then install my new carb! LOL
PS......please tell me these things are a bit tappy and knocky at idle. Remember, it has been 18 years since I had one of these 2 strokes. If I recall correctly, my one way back then sounded the same at idle. But, having 4 strokes the past 18 years, I am used to quiet idling. Here is an idle and low rev I took briefly (it was late and I am urban)
[video=youtube;U1BNjKI7F2Q]http://youtu.be/U1BNjKI7F2Q[/video]
Here's another with a rev or two
[video=youtube;WRLkjhlPmuY]http://youtu.be/WRLkjhlPmuY[/video]
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A little update. No pics right now, but may get some later today. Got to spend some time on the R yesterday. Went over every bolt on the thing, filled and bled the front brakes (they seem to work) and tried that on the rear, but the master cylinder leaks bad (off to find a nice one, maybe a 450R one). Removed the number graphics, mounted up all the fender hangers, replaced a bunch of fasteners, put a chain on it, etc. Fired right up, and let it warm up. Rode it gently for a few minutes. When stopping I noticed the knocking tapping seemed louder. Made another idle knock video. So, it looks like I am going to take the top end off and see what I find. I would assume I can check for play in the crank and lower rod bearing, after taking the cylinder off, right? Off to find my service manual.......
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Plastics off.....
(http://img.photobucket.com/albums/v163/jimbo45/20141227_144359_zps8o3hefwy.jpg)
Taking stuff apart............
(http://img.photobucket.com/albums/v163/jimbo45/20141227_144352_zpsmng8m0kg.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/20141227_144421_zpsnnqcdlvb.jpg)
Engine mount and coolant hoses off.....
(http://img.photobucket.com/albums/v163/jimbo45/20141227_151214_zpsqorwcyzq.jpg)
Carb and pipe off.....
(http://img.photobucket.com/albums/v163/jimbo45/20141227_153826_zpswbpsaju8.jpg)
Head is off...... looks like a small squish area, is this a normal '86 head?
(http://img.photobucket.com/albums/v163/jimbo45/20141227_155225_zpsvuq2htlp.jpg)
Some scoring in the cylinder, and apparently a domed piston. It was OK to run 93 octane in this???????
(http://img.photobucket.com/albums/v163/jimbo45/20141227_155314_zpscqvzdiqu.jpg)
Jug off, and from my chainsaw repair experience, I know that these marks on the piston are not desirable......
(http://img.photobucket.com/albums/v163/jimbo45/20141227_160653_zpshzmgdqrl.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/20141227_160915_zpsnus3kxye.jpg)
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Crankcase looks pretty clean. The con rod feels pretty good. I detected only a very slight amount of up and down movement in the con rod bearing. Just enough to notice, I think it is good for a while, at least I hope so. I didn't notice any crank bearing slack. The wrist pin bearing felt a little loose, but that was without the pin in it, so maybe normal.
(http://img.photobucket.com/albums/v163/jimbo45/20141227_163242_zpswhhx5vbu.jpg)
Jug bottom....
(http://img.photobucket.com/albums/v163/jimbo45/20141227_164206_zps4zphfigv.jpg)
Cylinder and head......
(http://img.photobucket.com/albums/v163/jimbo45/20141227_164309_zpske0dbsec.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/20141227_164335_zpsa2aipyin.jpg)
All ready to roll back into the corner, lower cases covered, waiting for a top end......
(http://img.photobucket.com/albums/v163/jimbo45/20141227_185152_zpsfeeokeqc.jpg)
Now, to determine the size of the piston, and decide where to get the work done.......
(http://img.photobucket.com/albums/v163/jimbo45/20141227_190443_zps1nmhvkxl.jpg)
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"Here's yer problem!" See video below. The piston had probably more than 1mm of movement in the bore. Guess that was the loud knocking that I heard. I wish I had someone local, that could mic the bore, so I could know what size piston to order. I know that the piston is a 68mm. It still measured 68mm at the center of the skirt, but I suspect the upper and lower diameters were worn down to less than 68mm, causing the play. So what size piston do you guys think I could go with and bore to?
[video=youtube;gPRGFL7rYvM]http://youtu.be/gPRGFL7rYvM[/video]
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Hmmm, looking at Pro-x pistons, 68mm is the biggest they sell. I wonder if I could get away with just a hone job and a new 68mm piston? Or, bore it, and get a 68.5mm or 69mm Wiesco piston. Man, I really need someone to mic this cylinder, so I can know which direction I can go.......
Another question for you guys.....this R has a Nology coil and plug wire, that is super long, and you can see the huge loop it makes on the stator side of the engine. What the heck? There probably isn't a good way to sorten this, since it has the ground wire on it, that hooks to the head. Must it be that long?
Picked up a re-sleeved oem top end with 69mm piston, with some life left in it, from 250Ryan today! Thanks bro! Now if my wrist pin bearing arrives before the weekend, I may have this project moving!
(http://img.photobucket.com/albums/v163/jimbo45/20141229_143837_zpsbk6mott1.jpg) (http://smg.photobucket.com/user/jimbo45/media/20141229_143837_zpsbk6mott1.jpg.html)
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New PWK 38 Airstriker! Woo Hoo!
(http://img.photobucket.com/albums/v163/jimbo45/20150104_152816_zps8drdeawt.jpg)
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450R rear master cylinder obtained......
(http://img.photobucket.com/albums/v163/jimbo45/20150104_153029_zpsbaob0j2b.jpg)
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Swapped the reservoir and tube and inlet, drilled the threaded mount holes out, and swapped the 250R actuator rod in, and the 450R master cyl is mounted up! Time to head out and bleed it, and see if it works!
(http://img.photobucket.com/albums/v163/jimbo45/20150104_175341_zps3inl84oo.jpg)
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Got the gasket set in today and the dowell pins. I didn't realize the engine only used 2 dowell pins on the left side. Doh! I figured each of the four studs needed a dowell pin on the cylinder studs. I wondered why it wouldn't slide all the way down. LOL
I got the top end assembled, and the pipe reconnected, and the new Keihin PWK 38 AS card mounted, but try as I might, even with boiling water, I could NOT get the stock airbox boot on the carb. I heated and stretched, but it was a no go. My boot is kind of ratty, and I was afraid it would split if I pulled any harder on it to stretch it. I guess I will look for an nice stock boot, and boil the crap out of it, and use someting like a shoe stretcher, and make the boot bigger. Man, so many set backs, I WANT TO RIDE THIS BEAST! Here is a pic I took with the new / used top end on.....
Ordered a better used OEM airbox boot (mine was ratty around the carb end) and a reed spacer, to hopefully get this new carb mounted up correctly. To be continued.......
(http://img.photobucket.com/albums/v163/jimbo45/20150108_202004_zpskr0guvob.jpg)
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Did some rear axle work tonight. Checked things out and greased the rear end. The back is ready to go! I WILL need a new sprocket hub this summer though, this one is getting a bit of play.
(http://img.photobucket.com/albums/v163/jimbo45/20150112_143119_zpsgeutp8mt.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/20150112_152925_zpsufzo8ipe.jpg)
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The plastics cleaned up great! Put some oem 88 style decals on, it sure helped the looks! It looked so plain before.
(http://img.photobucket.com/albums/v163/jimbo45/20150113_144535_zpsktwiyayr.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150113_144535_zpsktwiyayr.jpg.html)
(http://img.photobucket.com/albums/v163/jimbo45/20150113_144631_zpsg133z3e8.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150113_144631_zpsg133z3e8.jpg.html)
Got my reed spacer and new used boot. Boom! Got the boot to fit! Now, just if I can get it on the quad with the boot attached to the carb....
(http://img.photobucket.com/albums/v163/jimbo45/20150116_102204_zpsa9dn3n7u.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150116_102204_zpsa9dn3n7u.jpg.html)
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Airstriker mounted! Now to figure out this throttle cable and fill it with coolant.....
(http://img.photobucket.com/albums/v163/jimbo45/20150116_115622_zpss2uauiq1.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150116_115622_zpss2uauiq1.jpg.html)
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Did some work on the R.
I went over all of the wiring and connections, replaced some, greased all, and made new ground point. I also checked the Nology coil....about .15 ohms between the posts, and about 6 ohms between the post and plug socket. SOmething is wonky with it, I think the Nology coils are supposed to be over .4 ohms. I noticed weak to no spark yesterday, and ordered a nice used OEM coil. Hoping that will fix it.
Took off the head, and cleaned up the gasket surfaces surgically clean, and installed the spare wiseco gasket that I sprayed with several coats of copper gasket spray, two days ago, and let it dry. Carefully torqued the head in several steps, to 22 ft lbs. Hoping this one won't drip coolant. Here is a pic of the super thick sleeve. I think the coolant is leaking around where the sleeve meets the cylinder, which is super close to the water holes.
(http://img.photobucket.com/albums/v163/jimbo45/20150119_150744_zpsxnldsklz.jpg)
I also lined up the front end. The right front wheel leaned in like an inch at the top, and the toe was out. Still need to straighten up the top heims, I just noticed they are not square to the ball joints.
(http://img.photobucket.com/albums/v163/jimbo45/20150117_204024_zpsvuxdhvz3.jpg)
I couldn't run it much, but I did start it, and warm it up, and hit the throttle a few times. Seems the electrical work did some good, it stays running now, and was easy to get started. It did break up with revving it quickly, and blew a lot of smoke, so either the coil is not working right, or the needle and main are WAY rich. On a good note, I didn't see any coolant dribbling out of the head....yay! While not a true test, it is encouraging. When my coil comes in later this week, I will retorque the head nuts and put in the coil, and see how it goes.
Well CRAP!!!!!!!!!!!!!!! After putting in the second Wiseco gasket (this one coated with permatex copper gasket spray), and I trued up the sealing surface of the head, it leaked a tiny bit. The head was carefully torqued in steps, to 22 ft lbs. Not as bad of a leak as before, but after a 10 minute rip around the empty lot next door, a few coolant bubbles appeared. CRAP! I really think it is because of the super thick sleeve in the cylinder, that was maybe installed improperly? There is a bit of a gap between the sleeve, and the aluminum cylinder, and it is so close to the water jackets, I can see why some coolant is leaking. One of the cyl nuts had a coolant drop and several drops squished out around the circumference of the head gasket.
Do you think a OEM style gasket, ground to 69mm, is worth a shot, trying here? I am not sure what one of those costs, but if its not terribly pricey for the gamble, I may try that. I guess if that is not gonna be a reasonable try at a solution, I will have to save until late summer, and have my original cyl and head bored, trued, and head matched, and a new piston. I will have to park this thing until then if that is the case. *sigh* I already have way too much money invested in this "play quad" that I don't really have to be spending on it. :mad: See pics of sleeve before I put on the second wiseco gasket, and pic of the coolant leak........
(http://img.photobucket.com/albums/v163/jimbo45/20150119_150744_zpsxnldsklz.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/20150120_160713_zpshtdygwrc.jpg)
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Took the head off again and MAN was that copper sealer hard to carefully clean off! Put on the new 3 piece oem gasket, and used my other head this time (the '86) and carefully torqued it down. I also put a new 5ohm boot on the new to me oem coil, and installed that. Swapped a 45 pilot in place of the 50, since it was way rich idling. Warmed her up, and took it for a few minute rip.....it runs awesome, and I didn't see any coolant coming out of the head yet! This may have finally done it! Now, just some final jetting and some front end tuning, and I may actually be able to take it out for a ride!!!
(http://img.photobucket.com/albums/v163/jimbo45/20150127_162503_zpsvgoywaor.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150127_162503_zpsvgoywaor.jpg.html)(http://img.photobucket.com/albums/v163/jimbo45/20150127_162649_zpsinbt1p0y.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150127_162649_zpsinbt1p0y.jpg.html)
(http://img.photobucket.com/albums/v163/jimbo45/20150127_162753_zpslnwmpw7n.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150127_162753_zpslnwmpw7n.jpg.html)
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More carb tuning today and got the rear Hipers that came with it, installed today!
Just about ready to ride. Some jetting issues, but I am figuring it out. Seems it likes the #40 pilot and a #160-162 main in this weather. The DGH needle is a touch lean on the lower 3rd of throttle range, but works decent in the 4th clip position. I have two more needles enroute to try.
(http://img.photobucket.com/albums/v163/jimbo45/20150210_145113_zpsscrflbiw.jpg)
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Ok, this thread is caught up to now, on this forum! THanks for having me, guys!
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Good looking build!
Welcome over!
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Got my front hipers installed tonight. Let the black wheel hate begin! LOL
Now, I just need a black AC front bumper and a few little odds and ends, and for my Elka's to arrive, and I will be in business for a while. I am considering powder coating the nerfs and rear bumper black as well someday.
(http://img.photobucket.com/albums/v163/jimbo45/20150218_224839_zpsvvuxvisk.jpg)
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it looks good with all the rest of the black on there :) one day i want to build a completely blacked out bike, with contrasting gloss and matte parts.
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Thanks Jesse. I know some don't like black wheels, and I understand. I thought my dad was gonna stroke out when he saw the black wheels on my new truck. LOL. They are a different, more utilitarian look for sure. I honestly probably like the aluminum wheel look just as well, and they do have a more classic, classy look. I just always wanted Hipers for the durability and ease of tire swaps, years ago, when I saw the quad guys running them at the track, when I was riding dirtbikes at the track. And when I acquired this R, the owner included a set of new rear Hipers, so I went for fronts too.
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looking good jimbo..
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Nice lookin R you have there
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Thanks guys! Man, in the pics, the black wheels make the tires look HUGE! They are 18" on the back and 22" on front.
I got a couple more needles to play with, a DEG and a DGG, to hopefully richen just off idle a bit. Once I get the best tuning, it is finally ready to RIDE! Well, once we get temps above 7, Lol.
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Turned out real nice!
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Thanks! I am not done quite yet.
I did get some cold weather tuning done today. For frigid, 10 degree weather, the DGG needle in the fourth notch, and the #40 pilot @ 1-1/4 out, and a #162-160 main, seem to be about perfect!
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New bumper and new front master cyl
Old bumper:
(http://img.photobucket.com/albums/v163/jimbo45/20150227_135324_zpsuzwkpuz0.jpg)
New bumper:
(http://img.photobucket.com/albums/v163/jimbo45/20150227_142043_zpsxjdy30ba.jpg)
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I reworked the chopped up race harness, and fixed it to add an OEM kill/light switch, tail light and head light, and a voltage regulator. Completed my self made new wiring harness, with new factory connectors! Also, got the '88-'89 style hood and light mocked up, while waiting on the headlight rubber bushings.......it lights up great!
(http://img.photobucket.com/albums/v163/jimbo45/20150319_181315_zpsrx8r07ja.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/20150319_183018_zpscqibezru.jpg)
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I like the red/black combo on this. Looks like a nice rebuild!
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I like the red/black combo on this. Looks like a nice rebuild!
Thanks! Its actually Orange/black, but its hard to tell with my crappy flourescent lighting in the pics. I need to get it outside as soon as the weather permits. You can see the rain in the background I think, lol.
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That headlight hood is actually a new fighting red Maier hood, that I plasti dipped black, then put like 6 coats of glossifier on. I hope to get red plastics some day, and peel that plasti dip off! Looks good for now, though! lol
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Oh my bad...even better. I always wanted to do one with alot of black and then orange fullbores.
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Got my headlight built with a mix of oem parts and collars from the hardware store! Ready to bolt on and plug in. I do have the long screw adjustment hardware, but need to add a tab to this 300ex light, for it to work. I dunno, might not even do that, it seems fairly solid without it.
(http://img.photobucket.com/albums/v163/jimbo45/20150326_194726_zpsggmhxtu9.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150326_194726_zpsggmhxtu9.jpg.html)
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nice jim, where did you get those decals? i see them on many bikes, never seen where they come from before though. my bike when i bought it even had them on it lol.
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nice jim, where did you get those decals? i see them on many bikes, never seen where they come from before though. my bike when i bought it even had them on it lol.
Here:
http://www.ebay.com/itm/Stickers-Decals-Graphics-For-TRX250R-TRX-250-R-250R-Fender-Hood-Plastics-Tank-/321426535053?var=&hash=item4ad683b28d&vxp=mtr
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I decided to go ahead a put an adjustment tab on this 300ex headlight, since I had the screw, washer, spring and nut. I just fabbed a 90 degree piece of aluminum and drilled some holes, and JB welded it to the light. Should work out great and I will install it once its cured.
(http://img.photobucket.com/albums/v163/jimbo45/20150327_215456_zps4krevu5e.jpg)
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Hey guys, put the new top end on last night. Quick advise before I button it all the way up...........
I have a short rod motor, and this cylinder that CT did, has been resurfaced/decked. I first put it together with just one cometic .020" base gasket, and looked to the piston height at TDC. It looked like the edge of the piston was about even with the deck. That had me a little concerned on squish clearance. So, I put a second .020" cometic base gasket, and it appears the piston is now about .020" below the top, with two base gaskets on there (estimating). I am sure it would have worked out with just the one base gasket, since CT did this cyl and head and they provided the gasket set. But, I think I will run the two base gaskets, to be on the safe side, and especially since I am not after max horsepower anyway, and will be running Pump/race gas mix.
My concern is the change to port timing, since I raised the cyl .020" over stock. Is that a big deal? Should I not run the two base gaskets, and instead just put one in and do a solder squish test? (Problem is, I already torqued the head down, and not sure I can reuse the layer head gasket again).
Here is a pic of the piston height with two base gaskets......
(http://img.photobucket.com/albums/v163/jimbo45/20150329_232029_zpsqsbz5qzg.jpg)
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Looks fine if you are using the standard .078" or 2mm head gasket. If you use 2 base gaskets you should have put some sealer on there. Base gaskets are available in many different thicknesses so you only have to use one without worrying about leaks.
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The head gasket is a .040" Cometic 3 layer gasket.
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looks good to me
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The head gasket is a .040" Cometic 3 layer gasket.
ah hell...maybe the resurfacing will compensate for the thick gasket, or take a base gasket off
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ah hell...maybe the resurfacing will compensate for the thick gasket, or take a base gasket off
Yeah, I am gonna check squish in the morning, and may end up pulling one of the base gaskets, if it figures out to have enough clearance that way. I should be able to do all that without removing the head.
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Things have escalated....
(http://img.photobucket.com/albums/v163/jimbo45/20150331_122508_zpsocxje1ut.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150331_122508_zpsocxje1ut.jpg.html)
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(http://img.photobucket.com/albums/v163/jimbo45/20150331_123127_zpsg0kziwn0.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150331_123127_zpsg0kziwn0.jpg.html)
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ohhhh sooo nice
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I'm jealous
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I'm jealous
I got my '88='89 style headlight collars fabbed up, thanks to your measurements!
(http://img.photobucket.com/albums/v163/jimbo45/20150331_213159_zps4b34yqku.jpg)
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Elkas are installed! For a few minutes, I was trying to figure why the rear shock res hose was so dang long, and was trying to mount it in the stock location. After googling some pics, I noted that it is intended to mount up front. Sweet! More pics to come tomorrow, after a couple more heat cycles on the new top end, and I get plastic installed, and it all cleaned up!
(http://img.photobucket.com/albums/v163/jimbo45/20150331_210137_zpscaloklww.jpg)
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Question on the rear Elka shock.....it makes a "clunk" about 2/3 of the way through the stroke. It sounds like one of the plastic collars in between the spring stages is catching on a coil as the shock compresses or something. Is that normal? Its not that big of a deal, but it is a noticeable thud, and I can even feel it. Weird.
Edit to add: After setting the sag (it was way too soft out of the box), the clunk went away!
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Well, its done for now. I will probably powdercoat the bumper, grab, and nerfs black (or charcoal, if I redo the frame pc too) next winter, but for now its done. I didn't clean it up yet, but you get the idea. Thank you all for all your help and patience. I could not have done it without you. It is ready to GO! I put a few heat cycles on the engine, and have it jetted a bit rich for the first break in ride. Gonna set sag tonight and get ready for its maiden weekend!
Went through and checked/replaced/fabbed all the:
Bearings
Brakes
Master cylinders
Hiper Wheels
Fasteners
Built a factory style wiring harness for lighting
Added Headlight and tail light and OEM lighting kill switch
Top end
New Airstriker carb
Gaskets
Ignition
Hubs and bearings
Airbox and filter
New Elka suspension
(http://img.photobucket.com/albums/v163/jimbo45/20150401_172735_zpsn1ayvhjy.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/20150401_172750_zpskjdhglnp.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/20150401_172807_zpsjbimzzfx.jpg)
(http://img.photobucket.com/albums/v163/jimbo45/20150401_172829_zpsvq4l7cnn.jpg)
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Very nice jimbo. You should be proud.
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Very nice jimbo. You should be proud.
Thank you sir. I can't take all the credit though.
It is a budget build compared to what a lot of you guys have, but it will be perfect for what I need for now. Plus, there is always another project that can be done right? :)
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looks great man, enjoy!
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Excellent job. Pics and vids of the ride stat!
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It is a budget build compared to what a lot of you guys have
Budget builds don't have ELKA's:rofl:
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PROJECT 839 had its maiden. Got a little mud on the tires.
(http://img.photobucket.com/albums/v163/jimbo45/20150403_180017_zpsnj25zsst.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150403_180017_zpsnj25zsst.jpg.html)
Got more mud on the RZR though. This thing is a beast in the mud!
(http://img.photobucket.com/albums/v163/jimbo45/20150403_180156_zpshyjwut1h.jpg) (http://smg.photobucket.com/user/jimbo45/media/20150403_180156_zpshyjwut1h.jpg.html)