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PostPosted: Sun Feb 14, 2010 10:36 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Got parts in for this,so I started on the bottom end yesterday.I lapped the case halfes, then washed them in soapy water and installed the crank seals and bearings in both halfes.Lapped the head, this took some time as it was not flat,I found using some water on the paper worked wonders to help the process.Heres some pictures.I will install the crank, and shfit drum, gear shafts, and the shifter into the right side today-heres some pictures.The side cases have had a bit of material worn off in areas from some MUTT using a "wiz wheel" air tool to take the gaskets off, so I might have to lapp these alittle more in areas to get them perfect.If you see something please let me know!!

The crank runout was at 0.01 so that's well within manufacturers specs( 0.02-0.10) and the side clearance as well spec's in under so it will be re-installed as well.I'll have the ring gap and piston to wall clearances posted here in a bit.I was wondering though-the parts are cold, should I take them inside and have them warm up a spell before checking the gaps/clearances?Will there be a difference it them?


Attachments:
File comment: head, this took some time to get the surfaces clean and true.
tecate motor pic 001.jpg
tecate motor pic 001.jpg [ 1.26 MiB | Viewed 3376 times ]
File comment: new OEM bearings and seal installed, case lapped
tecate motor pic 002.jpg
tecate motor pic 002.jpg [ 1.37 MiB | Viewed 3376 times ]
File comment: other side, same deal
tecate motor pic 003.jpg
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File comment: new EBC clutch pack
tecate motor pic 005.jpg
tecate motor pic 005.jpg [ 1.18 MiB | Viewed 3376 times ]
File comment: box of goodies!!!!
tecate motor pic 006.jpg
tecate motor pic 006.jpg [ 1.24 MiB | Viewed 3376 times ]
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PostPosted: Sun Feb 14, 2010 10:48 am 
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Joined: Fri Jun 19, 2009 4:33 pm
Posts: 432
Location: long island NY
Mudbogger you can use wd40 when your wet sanding.it makes it alot easyer


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PostPosted: Sun Feb 14, 2010 11:03 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
I have heard that from STONEMAN as well.I used water with a drop of soap in it, it really helped the process!


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PostPosted: Sun Feb 14, 2010 2:38 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Got some work perfomred on it today-crank in,trans installed with hardware-kicker in with gears-here some pictures.
I measured the ring gap and piston-jug for clearances:
ring gap for both rings set just below the skirts 0.4mm (as per manual that's stock)
Jug top is 69.58mm
jug bottom is 69.82mm
Piston top is 69.55
Piston bottom 69.75mm

that's gives me 0.03 piston wall clearance on top and 0.07 on the bottom with the new OEM jug and Piston set.Standard as per manual is 0.049 - 0.059mm.


Attachments:
File comment: clutch dry fitted to make sure all the spacer and washer are correct.
tecate motor pic 007.jpg
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tecate motor pic 008.jpg
tecate motor pic 008.jpg [ 1.38 MiB | Viewed 3376 times ]
tecate motor pic 009.jpg
tecate motor pic 009.jpg [ 1.42 MiB | Viewed 3376 times ]
tecate motor pic 010.jpg
tecate motor pic 010.jpg [ 1.32 MiB | Viewed 3376 times ]
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 Post subject:
PostPosted: Sun Feb 14, 2010 2:45 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Mudbogger wrote:
Got some work perfomred on it today-crank in,trans installed with hardware-kicker in with gears-here some pictures.
I measured the ring gap and piston-jug for clearances:
ring gap for both rings set just below the skirts .016mm
Jug top is 69.58mm
jug bottom is 69.82mm
Piston top is 69.55
Piston bottom 69.75mm

that's gives me 0.03 piston wall clearance on top and 0.07 on the bottom with the new OEM jug and Piston set.


Recheck the bore taper I never seen a new OEM cylinder with taper like that


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 Post subject:
PostPosted: Sun Feb 14, 2010 2:58 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
ok, will do.I am looking at my old measurements from the old jug I sent out, the taper is quite lareg in that one as well.old jug was:
69.74 top
69.85 bottom
piston was:
69.67 top
69.82 bottom


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PostPosted: Sun Feb 14, 2010 4:41 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Any ideas on how I can check to insure the crank has gone all the way inot the bearings?It slid right in to the bearing with a very light coating of ANIT-SIEZE on it, but I am unsure if it is all the way.Any thoughts?


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 Post subject:
PostPosted: Mon Feb 15, 2010 10:09 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Got the bottom end assemblied today, dry fitted it once to check for sure everything was on the up and up, then I reassemblied it using the YAMABOND.The top end will be completed in the coming week hopefully.


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 Post subject:
PostPosted: Mon Feb 15, 2010 11:35 pm 
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Joined: Mon Jun 15, 2009 3:05 am
Posts: 1228
Location: Chicago
Mudbogger wrote:
Got the bottom end assemblied today, dry fitted it once to check for sure everything was on the up and up, then I reassemblied it using the YAMABOND.The top end will be completed in the coming week hopefully.


when do i get to ride it?


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 Post subject:
PostPosted: Wed Feb 17, 2010 6:48 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
US CHROME called today-the old jug has been completed with replating and a fresh piston kit.Being that the turn around was so quick I may just re-use this 1 and save the OEM jug for a later time.They (uschrome)match the piston to wall clearances for you right at the factory when they plate them, so it should be right on!


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 Post subject:
PostPosted: Wed Feb 17, 2010 8:00 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Mudbogger wrote:
US CHROME called today-the old jug has been completed with replating and a fresh piston kit.Being that the turn around was so quick I may just re-use this 1 and save the OEM jug for a later time.They (uschrome)macth the pistonto wall clearnaces for you right at the factory when they plate them, so it should be right on!


Save the OEM cylinder run the rebuilt cylinder...


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 Post subject:
PostPosted: Wed Feb 17, 2010 10:11 pm 
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Joined: Wed Sep 29, 2004 4:48 pm
Posts: 1037
Location: CT
Mudbogger wrote:
US CHROME called today-the old jug has been completed with replating and a fresh piston kit.Being that the turn around was so quick I may just re-use this 1 and save the OEM jug for a later time.They (uschrome)macth the pistonto wall clearnaces for you right at the factory when they plate them, so it should be right on!


They should set the piston to wall clearance. The plating is very hard and is not supposed to be honed with a normal hone. Trying to hone a plated cylinder can damage it - usually the coating will begin to flake on you.


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 Post subject:
PostPosted: Thu Feb 18, 2010 7:25 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Correct, US CHROME spoke to me about the processes and never to bore these jugs ever.BTW do you happen to know whay KAWASAKI jugs have so much taper in them by chance?


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 Post subject:
PostPosted: Thu Feb 18, 2010 11:16 am 
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Joined: Mon Sep 08, 2008 1:28 am
Posts: 708
Location: Melbourne, Australia
Mud, you're a rebuilding machine!!

You do great work & so fast too.

There must be a lot of guys out there that 'owe' you bigtime for you to 'acquire' all those OEM parts for your rides. :-)


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 Post subject:
PostPosted: Thu Feb 18, 2010 7:25 pm 
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Joined: Wed Sep 29, 2004 4:48 pm
Posts: 1037
Location: CT
Mudbogger wrote:
Correct, US CHROME spoke to me about the processes and never to bore these jugs ever.BTW do you happen to know whay KAWASAKI jugs have so much taper in them by chance?


I don't know for sure as to why there is so much taper. At operating temp the cyl may loose its taper. Power valves will change the heat characteristics of a cylinder (changing port timing) at different rpms's, so the taper may be engineered into its design. Help prevent ring gap butting, sticking???
We always had great luck with kawasaki two stroke engines. Never lost a top or bottom end in years of racing. I never cared for their clutch baskets and internal linkage. Water pump seals like to weap.


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 Post subject:
PostPosted: Sat Feb 20, 2010 11:27 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
I am expecting the old jug to be here this week, after the re-plating I am curious as too the taper of it in regards to the OEM jug I purchased off Ebay.I'll take measurements and compare the 2 for shits and giggles.I installed the clutch friction and metal plates tonight, I got confused as to the metal plates-they are aftermarket EBC plates and one side is beveled, the other is a sharp edge-does it matter which edge goes into the clutcj housing,the package for the EBC clutch pack did not have any type of directions, and the manual does not state which way to insert them-got me puzzled for sure.Anyway, the bottom end is all done, I await the top end and should have this all together in the coming week hopefully.Any hekp on those metal plates is appreciated, I got the friction plates in fine, just those metal ones are bothering me.


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 Post subject:
PostPosted: Sun Feb 21, 2010 10:31 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Called EBC and posted a question in regards to this on the 3 wheeler board, according to both it does not matter which way you install them, just make sure they are all the same way-meaning flatside in on all, vice-versa-that's it!
Going to work on the trike itself today, need to install rear carrier bearings,clutch lever,kill switch,and some other goodies.Will post pictures later.I am not going to powder coat this ride, I want to make sure it is a reliable ride, which runs perfect before I even think of going to the restore mode on it


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 Post subject:
PostPosted: Sun Feb 21, 2010 11:11 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
some pictures of the bottom end:


Attachments:
File comment: Bearings -not crank, others for the gear shafts and all others
IMG00097-20100203-1531.jpg
IMG00097-20100203-1531.jpg [ 562.87 KiB | Viewed 3377 times ]
IMG00099-20100221-0938.jpg
IMG00099-20100221-0938.jpg [ 742.44 KiB | Viewed 3376 times ]
IMG00100-20100221-0938.jpg
IMG00100-20100221-0938.jpg [ 797.74 KiB | Viewed 3376 times ]
IMG00101-20100221-0939.jpg
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IMG00102-20100221-0939.jpg
IMG00102-20100221-0939.jpg [ 800.99 KiB | Viewed 3376 times ]
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 Post subject:
PostPosted: Sun Feb 21, 2010 4:50 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Installed new swinger bearings and seals, also the rear carrier bearings and seals too on the ride, the chain guide is scrap, and there were numerous broken bolts for the skid plate which I drilled and re-tapped on the swinger.It appears to me it has been welded in the front at some point-the tubes that accept the bearings look to me to be homemade,there's no stops on the inside for the bearings, that's weird to me, most of my other swingers have stops in them, I'll post some pictures when I get back home later.The rear carrier bearings are sealed 6007's


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 Post subject:
PostPosted: Sun Feb 21, 2010 7:25 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
pics


Attachments:
IMG00125-20100221-1253.jpg
IMG00125-20100221-1253.jpg [ 654.41 KiB | Viewed 3376 times ]
File comment: Is it me or do these look to have been replaced, there's no stops inside the tubes for the bearing to seat on --
IMG00126-20100221-1253.jpg
IMG00126-20100221-1253.jpg [ 891.46 KiB | Viewed 3376 times ]
File comment: rear carrier mounted with new bearings, these are really easy to do on the tecates
IMG00127-20100221-1254.jpg
IMG00127-20100221-1254.jpg [ 784.91 KiB | Viewed 3376 times ]
File comment: Back on the trike and ready for a shock
IMG00129-20100221-1534.jpg
IMG00129-20100221-1534.jpg [ 750.9 KiB | Viewed 3376 times ]
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 Post subject:
PostPosted: Fri Mar 05, 2010 8:26 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Got the cylinder back from US CHROME-here's some pictures for you.According to US CHROME the ports are not to be touched at all due to the plating.I also got a new intake which is made from a member on the 3 wheeler boards, the material is very durable poly rubber.


Attachments:
File comment: jug before re-plating
IMG00051-20100123-1744.jpg
IMG00051-20100123-1744.jpg [ 682.04 KiB | Viewed 3376 times ]
File comment: before re-replating
IMG00049-20100123-1743.jpg
IMG00049-20100123-1743.jpg [ 628.98 KiB | Viewed 3376 times ]
File comment: before pictures
IMG00072-20100123-1910.jpg
IMG00072-20100123-1910.jpg [ 616.22 KiB | Viewed 3376 times ]
File comment: after re-plating process
DSC00011.JPG
DSC00011.JPG [ 1.11 MiB | Viewed 3376 times ]
DSC00013.JPG
DSC00013.JPG [ 1.22 MiB | Viewed 3376 times ]
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 Post subject:
PostPosted: Fri Mar 05, 2010 8:30 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
more


Attachments:
DSC00011.JPG
DSC00011.JPG [ 1.11 MiB | Viewed 3376 times ]
DSC00019.JPG
DSC00019.JPG [ 1.16 MiB | Viewed 3376 times ]
DSC00012.JPG
DSC00012.JPG [ 946.98 KiB | Viewed 3376 times ]
DSC00014.JPG
DSC00014.JPG [ 1.27 MiB | Viewed 3376 times ]
DSC00016.JPG
DSC00016.JPG [ 1.05 MiB | Viewed 3376 times ]
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 Post subject:
PostPosted: Fri Mar 05, 2010 8:32 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
more


Attachments:
DSC00015.JPG
DSC00015.JPG [ 1.14 MiB | Viewed 3377 times ]
File comment: v-force3 reeds
DSC00017.JPG
DSC00017.JPG [ 986.38 KiB | Viewed 3377 times ]
DSC00018.JPG
DSC00018.JPG [ 1.39 MiB | Viewed 3376 times ]
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 Post subject:
PostPosted: Fri Mar 05, 2010 8:35 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Ordered a RICKY STATOR flywheel and stator 80 watt today as well for the bottom end.


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 Post subject:
PostPosted: Sat Mar 06, 2010 2:39 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
motor (( Internal Combustion Engine ? )) is completed, just need the stator and flywheel, which is on it's way.The piston was prepped as per Hosers tech pages: http://pilotodyssey.com/pistonprep.htm and new rings installed with all new OEM gaskets, torqued per manual specs and is ready for bolt in.Here's some pictures:


Attachments:
IMG00156-20100306-1244.jpg
IMG00156-20100306-1244.jpg [ 644.38 KiB | Viewed 3376 times ]
File comment: that's the intake the gentleman makes on the 3 wheeler boards, worked well.I will air leak test tomorrow, want to gasket to set up.
IMG00157-20100306-1245.jpg
IMG00157-20100306-1245.jpg [ 502.13 KiB | Viewed 3376 times ]
File comment: Jug from US CHROME installed with new wISECO 70MM PISTON,wirstpin, bearing,all new V-force 3 reeds with stuffer(that's stock)
IMG00158-20100306-1245.jpg
IMG00158-20100306-1245.jpg [ 528.42 KiB | Viewed 3376 times ]
File comment: kicker side
IMG00160-20100306-1245.jpg
IMG00160-20100306-1245.jpg [ 490.68 KiB | Viewed 3376 times ]
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