Backup Bike

[atc007]

Yes it does. John Natalie is learning that this summer .. Happens to all of us no matter how hard we fight it. My buddy and I always laugh. we have a couple neighbors,,never change their oil. Hang their weed eater up, get it out next spring, starts in 3 pulls,,and this goes on for a decade... We have to tune and clean everything every year... I hear ya!

[onformula1]

It's amazing isn't it? Some people (me) have mechanical problems the minute a fly craps on something and others can ride around until a wheel falls off, oblivious to the fact that not a single bearing, seal or gasket isn't F'd up on their ride.

I'm going to clean up the cylinder and use it as is for now. I'll keep my eye open for a good one too. The power valve set up is worth more than a cylinder, but once it's bored you can't go back (at least not properly). At my age and with this bike being for the shorter rides it may even last me the rest of my life. Sad to think that. I was out in a public riding area this morning and of 30 guys I think I was the oldest one riding. There was one older guy there but he just came to watch. Aging sucks!

Stop it with that old stuff, it's all in the head.

Watch this video of Feets Minert

He and many others ride the over 80 year old Vet. Class in motocross almost every weekend!

http://motocrossactionmag.com/news/m...s-minert-video


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[YTZ drew]

At my age and with this bike being for the shorter rides it may even last me the rest of my life. Sad to think that. I was out in a public riding area this morning and of 30 guys I think I was the oldest one riding. There was one older guy there but he just came to watch. Aging sucks!

Nah, you're going to become one of the "ancient ones" as seen in the Metamucil Militia. Hopefully I will too. They appear at 1:43

https://www.youtube.com/watch?v=wPmOTp8Hr0c

[El Camexican]

Only time will tell boys, everything just seems to hurts more and be harder to see every year. It may be time to start looking for the dreaded Harley soon... or not.

[onformula1]

Only time will tell boys, everything just seems to hurts more and be harder to see every year. It may be time to start looking for the dreaded Harley soon... or not.[emoji38]

Na, those things handle poorly.


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[danbur55]

Ha gotta be tough to to get old. ( it has to be the dumbest thing we will do)

[El Camexican]

Got the liner matched to the cylinder today. 5 straight hours stopping only to change bits. What a task, People who do this for a living don't get paid enough. My hands are so cut up from the edges on the bottom of the liner I didn't even want to touch the phone to take "after" photos. Engine is together aside from the head and part of the power valve.

I was planning to blast and coat the frame among other things, but looking at it closely I don't think it even has a scratch on it. Maybe it just gets cleaned. Not my style, but It would be nice to get it running before Christmas.

[onformula1]

Got the liner matched to the cylinder today. 5 straight hours stopping only to change bits. What a task, People who do this for a living don't get paid enough. My hands are so cut up from the edges on the bottom of the liner I didn't even want to touch the phone to take "after" photos. Engine is together aside from the head and part of the power valve.

I was planning to blast and coat the frame among other things, but looking at it closely I don't think it even has a scratch on it. Maybe it just gets cleaned. Not my style, but It would be nice to get it running before Christmas.

Why didn't you just take the sleeve out and match it from the outside?

[El Camexican]

Why didn't you just take the sleeve out and match it from the outside?

As in remove it from the cylinder and then put it back in? I was of the belief that doing that (besides being difficult) required a bore afterwards due to distortion after heating it and putting it back in. Please explained the process, doing it that way might have been a lot easier.

[onformula1]

A sleeve is installed first then dipped in acid so the ports are etched-marked from the inside, then pulled out and milled & port matched then reinstalled.

The outer cylinder gets heated and the sleeve almost falls out, the sleeve doesn't get that hot.

There is more to it, but I type slow plus you know the number,,,

[oldskool83]

All this ktm talk is making me want to pick up the 1 of the 2 ktms up the road from me at a garage, 85 and 86 enduros. Your KTM is pretty nice EL!

[El Camexican]

Well after an e chat with OnF1 regarding power valve clearance last night (the large valve was rubbing on the piston in the old set-up) I spent 3 hours tonight jacking with the power valves.

The fun started with the manual showing the 380 set-up and not the 300 which is different. Then there was the issue the gears not having alignment marks which I “think” were an upgrade because my other engine has them. When I finally got things lined up I realized the two smaller valves (there are 3 in total) where switched around.

I never did get my head around what that was doing to the engine, but when everything was installed properly it became apparent the main power valve (the one that was rubbing) had been adjusted about 8mm lower than it should have been.

Good news is that everything is in place; bad news is there is at least .060” of clearance between the piston and worn power valve flap. I guess time will tell if it is going to have a large effect on the low end power. I’m hoping not as there are plenty of other places around the stock setup that allow pressure to bleed.

Picked up a spare cylinder and PV yesterday, so happy about that.

[onformula1]

^ Give it a try, in the modern MX bike era top tuners are running lower compression, I have seen more heads rechambered for less compression than stock then heads rechambered for more compression and not because of today's fuel.

I build a lower compression Honda CR500 that felt like a very, very fast CR250, but would smoke a stock CR500 and if you ever rode one of those they are no slouch!
That thing was a blast! and yes it was still a "rock crawler" it lugged like a trials bike. I miss that bike, plus you could start it with shoes on!

[El Camexican]

Two steps forward one step back…

Dropped the engine in and bolted almost everything up. Had to leave the PV cover off the right side because I managed to lose both the new clips I bought between my mailing address and home and the head just came back from Slavens. Bolted the head on and took a compression reading of 180psi, up from 140 with the old head and the wrong base gasket.

So with the engine sitting in the frame it occurred to me that I should do a leak-down test. That’s when the fun started. It wouldn’t hold 6psi for 6 seconds, so out came the soap spray. Leaking base gasket, so I pulled the engine out and removed the jug for a light coating of case sealer on each side of the .002” thick gasket and again the engine was pressurized.

Still leaking fast, this time from the exhaust gasket, so again case sealer was used. Pressurized it again and it started leaking from the factory welds on the exhaust flange. At least 1/3 of the weld didn’t penetrate between the two parts, so I removed the flange and stuffed the plug into the port and pumped it up again. Still leaking!!! But where???

I ended up soaking the entire engine and couldn’t get a bubble out of it even though it was bleeding off 5psi per minute. Couldn’t hear anything either, so I uncovered the left side crank seal. No leak there so I removed the right side covers to check the other side of the crank, no leak there either, but wait! No more pressure bleeding either!
It held 6psi for 10 minutes, wtf???

I turned the crank slowly and tried to get it to leak, but it didn’t, so I decided to put the covers back on. The whole time the engine is holding pressure, when I went to press the PV rod on I hear a sharp “pssssst” and the gauge dropped to zero. I screwed with it for 20 minutes and could get it to stop leaking with a light touch of a finger, but I couldn’t get bubbles to form. I’ll live with it.

Color scheme is going to be very un-KTM, pics and fire up next week.

[onformula1]

White?...