Thanks Stix I hadn't had time to look for it yet. I'm thinking that the fourth one is for the starter. I hope so anyway. LOL Thanks Billy

No problem, I have some extra time on my hands so i thought I would try to make it a little easier for ya, Yep I think your right about the starter, arent there a couple O rings or seals in the starter?

yes there are and I do appreciate the help. I think my brain was running in low gear yesterday. LOL Thanks Billy

Does anyone have a picture of the front of the Engine with it mounted in the frame before the seat was installed? I am trying to come up with a different way for the balancer mod. Thanks Billy

Finally got to install all of the bearings and seals. hopefully I will get to install crank and get the bottom end together this week. May get it back in frame by late next winter with the way things are going. LOL I will get some pics. up soon. Thanks Billy

Got my crank with new rod, bearings ,pin and shims back today, hope to start reassembly by this weekend. Any advice before I start on the lower end? I plan on redoing the balancer mod. before assembly. Thanks Billy

Who did your crank work, and how much? I've got one that needs a new rod.

A friend of mine that works at a Honda dealership in Gadsden Al. While he had it apart he cleaned the crank and removed the rough casting surface with a wire brush. I think that he gets $75.00 + taxes for labor if you send him the parts. Thanks Billy

Ok got the bottom end put back together yesterday. Here are a couple of pics.

And some more pictures. Thanks Billy

I finally got the cooling fins removed the way that I wanted, so I started on the outer shell of the cylinder. This is just a test fit but, I think around the intake and exhaust ports will be the hardest. The rest should be easier.

I got my divider installed on my cylinder last night, and the outside jacket above the intake side of it also.

I finally got the outer jacket welded on the cylinder last Friday, I started today on the inlets for the head and the cylinder. It don't look that good but I ain't no welder. LOL But as long as it works I'm good with that.

I need some advice on reeds, I have been running the steel one that I guess are OEM. I figure that since I am doing the rebuild I should look at reeds and see which ones are the best across the board. I have studied up on them but of course everyone says theirs are the best. So I know that there are a lot of you that have ran different ones so like I said all advice is needed.

It is to be bored to 81mm over size carb. ported and polished exhaust ports, water cooled head and cylinder. I would also like some input on stuffers. The good, Bad and ugly on it. Thanks Billy

Update I have everything ready except for the piston and bore. I have a piston and when I took it out of the box, it was the wrong size. To make a long story short I had to order another one from another place to get it here this week and I will deal with the wrong one later. But it is out for delivery today so off to the shop in the morning for bore job. Also while this is going on I decided to repair my pull start cap it has always been in bad shape so now is the time to "Get R Done". Here are a few pics of it and after I get it finished I will post some more of it. I haven't heard anything back about reeds or stuffers so I guess I am on my own on that one. LOL Good enough! Thanks Billy

Thank you, That seems to answer all of my questions. So now I don't feel like such a D.A. When I road 2 strokes in the 70's-early 80's I stayed up on 2 stroke engines and improvements. But when I switched to 4 strokes I never looked back. This is the first one I have messed with other than weed whackers since then so I have a lot to catch up on. But that was a good post and very informative. Thanks again Billy

Update, I got my bore done on Friday to 81mm. Exhaust bridge work done also. Holes drilled in the piston and my exhaust ported and cleaned. I have also got more work done on the pull start cover, I'll post some pics. later today. I had to get my phone fixed, I couldn't even take a picture. Thanks Billy

That's a sexy lookin Engine to me.

Thanks, But I figure if it don't run good at least it will look good. LOL

Can you post a couple of pictures of the head and cylinder in/out water ports ??

Ok this is the first pics that I have tried since the phone dumped. I haven't cut the inlet pipes yet. I'm waiting until I sit it in and mount the radiator in place. Or I think that is what I'm doing. LOL

could have gotten AN weld on bungs and made all your line nice and need with AN fitting.

have you pressure tested the head and cylinder yet

I think I read earlier in the post where he did pressure test and only found two small leaks
to fix.
My set up is similar but I used screw in type hose barbs.
Both my oddy's never got hotter than 120'F and that's way to cold. Pulled the exhaust on mine and looked in. Seen some scaring in the intake wall. I now have a probe installed that turns pump on at 185'F off at 170'F. Have not had a chance to re-test run it yet. Maybe in the next couple of days.

Yes I did test and like CO said I found a couple of leaks. But I'm coating it with ceramic on the inside also, For anything that may develop in the future. I did look at weld on fittings and just decided to go with straight tubing since I already had it. But you are right it probably would have looked better. Really I am trying to for dependability over everything else. I ride in a pretty big area and I can't take the chance of breaking down far from the truck. The guys I ride with are on 4 wheelers and I catch hell if something breaks. LOL But it is all in fun. Thanks Billy

I've got all of the cracks and broken ears welded, but not finished. I am thinking of placing gussets on all of the bolting points.