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PostPosted: Mon Jul 14, 2014 4:52 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Mudbogger sent me two engines out of the Throttle Pilots this is Engine #2

Good packing


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PostPosted: Mon Jul 14, 2014 4:55 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Engine competently soaked in oil, WHY?

After every ride trip/weekend I remove my seat so I can inspect my Pilot and so I can wash it then change the balancer and transmission oil, pulling the seat would uncover problems like this.


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PostPosted: Mon Jul 14, 2014 4:57 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
After plugging up all the holes and over an hour in the sink scrubbing the shit off so the Engine is clean enough (first layer removed) so the Engine can be disassembled.


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PostPosted: Mon Jul 14, 2014 5:01 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Head removed, strange burn pattern plenty fat on the jetting that's for sure, head has slight damage from a past poofkaboom failure of something, not damaged enough to worry about machining the damage out just something that is noticeable, head is stock.


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PostPosted: Mon Jul 14, 2014 5:02 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
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Location: Chicago
One of the cylinder studs is not seated properly someone has removed in the past then did not properly reinstall, all 4 studs are rusted to shit and need replaced, so do all the cylinder nuts and cylinder dowels .


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PostPosted: Mon Jul 14, 2014 5:24 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Cylinder off and the gasket off you can see SAND stuck to the bottom side of the gasket where they used a very light layer of silicone sealer on the gasket to get it to seal.

SAND in all 4 of the case voids, looks like someone just rebuilt the Engine at the dunes? How do you reinstall the top end with all that SAND in the Engine, how much got into the crankshaft area I cant see how you could get sand in the case voids and not in the crank.

How come the sand in the voids was not sucked out with a vacuum cleaner before assembly?

You can see some of the green gasket left from a previous rebuild.


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PostPosted: Mon Jul 14, 2014 5:26 pm 
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Location: Chicago
Cylinder before hone


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PostPosted: Mon Jul 14, 2014 5:29 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Cylinder after being honed with a ridged stone hone.

See how the ridged hone does not follow the uneven cylinder wall.

You will have a hard time convincing me the cylinder was honed when the last new piston was installed.


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PostPosted: Mon Jul 14, 2014 5:30 pm 
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Location: Chicago
More detail pictures of the piston later.


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PostPosted: Mon Jul 14, 2014 5:31 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
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Location: Chicago
Everything in the balancer case looks good and normal looks like the bottom end has never been apart.


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PostPosted: Mon Jul 14, 2014 5:34 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Engine came with the oil cap cross threaded and not fully seated perhaps this is where the oil was leaking and covering the whole bottom end of the Engine?


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PostPosted: Mon Jul 14, 2014 5:35 pm 
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Location: Chicago
All 4 cylinder studs rusted up needs replaced.


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PostPosted: Mon Jul 14, 2014 5:38 pm 
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Location: Chicago
The crank cases has damage to them looks like something got between the crank and the cases perhaps a busted part of a piston?

The one case will need a weld repair.


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PostPosted: Mon Jul 14, 2014 5:41 pm 
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Location: Chicago
Can see where the crack in the crank case was leaking into the voids of the crank cases by the trail of black oil/greasy crap that gets thicker as it reached the bottom of the Engine.


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PostPosted: Mon Jul 14, 2014 5:42 pm 
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Location: Chicago
Aluminum flakes found behind the bearing in the seal.


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PostPosted: Mon Jul 14, 2014 5:46 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Something I have never seen before in a Pilot cylinder is some HUGE casting flaw in the transfers, this will be removed before I reassemble this Engine, cant believe who ever rebuilt this Engine in the past never noticed this and removed them they are so big even if you have no porting tools or a dremel tool you could improve the flow by about 100% by taking a screw driver and a hammer and knocking the casting off so its not blocking 1/3 of the port tunnel, this is why the strange uneven burn pattern seen on the piston crown....


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PostPosted: Tue Jul 15, 2014 6:29 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Hoser I have the following here for this:
all 4 jug studs
jug dowels
crank bearings and seals(left and right)
think I have the jug nuts as well.
I ordered some right crank bearings seals and rod kits, also some right crank bearings off the thread in the Pilot parts section.
Ordered 5 Engine gaskets sets, they are being shipped direct to you-easier since I don't rebuild them :-)
What else sir?
Again, sorry for the dirty engines, I really feell bad about sending them to you in that shape(as we discussed in the chat)!!


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PostPosted: Tue Jul 15, 2014 10:41 pm 
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Posts: 3294
Location: Oklahoma City, OK
Since the rebuilder didnt clean cases (sand and gasket residue in voids) maybe he didnt catch the broken case at the bottom from the last poofkaboom, sucking in air, maybe he ran big jet to evercome lean condition and cause for wierd burn pattern on the piston. Just thinking out loud.


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PostPosted: Wed Jul 16, 2014 5:19 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
I thought this as well but checking the carb it had totally stock internals in it, weird very weird.


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PostPosted: Sat Aug 16, 2014 6:59 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Hoser what piston kit is needed for this please? Any other items other then the parts I listed??


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PostPosted: Sat Aug 16, 2014 11:26 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Mudbogger wrote:
Hoser what piston kit is needed for this please? Any other items other then the parts I listed??


From the PM I sent 21 Jul 2014 04:49 pm

hoser wrote:
Need enough stuff to do the 3 bottom ends, sounds like you have that figured out.

Main items is the bearings and seals, gaskets, looking at your parts list you ordered you covered even more..

You will need a stock or STD. piston kit for the one cylinder and a 80.5mm piston kit for the second cylinder. viewtopic.php?f=4&t=14511

don't forget about the wrist pin bearings.
2 extra reed cage gaskets maybe get some from Speed? viewtopic.php?f=46&t=13799

I have to look I think you still have one CR500 rod kit here?
The 3 gasket sets you ordered and had shipped here came the other day :-)

What about the top end for the 3rd bottom end your sending are you going to send it with the 3rd Engine?



Disregard the 3rd bottom end that is done lol

So to answer your question you will need a stock or STD. piston kit for the one cylinder and a 80.5mm piston kit for the second cylinder, you had said in another message you had ordered a bunch of other stuff you were going to send dowels and such?

If you need a more detailed list let me know, on a side note I was surprised to see a made in the USA SKF bearing in your last shipment for the 3rd bottom end only parts, didnt know SKF even made bearings in the USA any more :shock: .


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PostPosted: Sun Sep 14, 2014 8:31 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
HOSER did you get the parts box for this Engine by chance?


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PostPosted: Sun Sep 14, 2014 1:56 pm 
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Joined: Tue Jan 17, 2012 3:19 am
Posts: 7699
Location: Hope, B.C Canada
Picture 2263:
Looks like there is a piece of piston or something metal laying next to the crank.
There are scrap marks on the casing leading to this piece and scuff marks on the crank lobe.
Is that a piece of the piston ???


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PostPosted: Sun Oct 05, 2014 9:27 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Hoser I have the 80.5 piston here from Adnoh and I sent you the all the other parts for both engines, was everything there in the box?
Also sent you a std piston kit with it :-)


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PostPosted: Sat Nov 01, 2014 7:47 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Hoser sent the replacement piston for the rebuild, did you get it already? Thanks!


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