Two Stroke Motocross
Two Stroke Motocross Forum => General Two Stroke Talk => Topic started by: Coop on June 13, 2010, 08:43:54 AM
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If this is the wrong forum, please feel free to move it. I have had a couple guys ask me to keep them informed of the rebuild so I thought I would just start a thread to document the work start to finish.
I bought a 1994 KX60 for my nephew recently. I got it really cheap and it came with a new cylinder. The guy said it just needed a piston/rings/gasket kit, but I suspected bottom end issues because these 60's are known to for that. Upon tearing into the engine I found a bad crank; the lower rod bearing race broke and that is what fragged the top end. I hope to start ordering parts this week. The frame and swing arm are getting repainted OEM colors. This is not a restore, just a refurbish so my nephew has a good looking, clean running bike to ride.
I am looking for opinions on engine finish. Should I paint it, or sand/bead blast it?
At the guys house:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-1.jpg)
About an hour after we got home:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-2.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-4.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-3.jpg)
I spent about an hour the other day and finished tearing the engine down:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/cases.jpg)
Bad parts so far, well everything but the oil glass I broke, lol. I was pushing it out so the cases were bare for finish and I managed to hamfist it and crack the glass haha.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/badparts.jpg)
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I reckon bead blast it Coop, would look better than painting. :D
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Looks like a fun project.Keep us updated on your progress.As for the finish question,the answer is obvious-bead it,then polish it 8)BTW,that is one big arse mutha farkin cam chain in the bottom pic.Must be a KXF60-shame on you ;D ;)
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LOL I was wondering if anyone would make a four stroke joke when they saw the chain in that pic :D . I decided I am going to blast it, but I don't think I will polish it. I am sure the 10 year old it's for is going to beat it pretty quick, haha.
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Yesterday I ordered the Wiseco complete crank kit with bottom end gaskets and seals, complete piston kit with top-end gaskets, a new shift lever to replace the mangled one, the parts to rebuild the water pump, and found a bolt kit on eBay. More than half the bolts on this engine were stripped and I do not plan on putting them back in like that.
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Some of the parts came today:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/Parts.jpg)
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cool project coop. i prefer media blasting myself. always hated when people painted their engines. made them look like lawn mowers. LOL
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I only painted my KTM 495 motor with spray paint, because I think that the spray paint is stronger than the motor cases! Didn't bead blast it or anything because if I did I would be left with a pile of dust. :)
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I only painted my KTM 495 motor with spray paint, because I think that the spray paint is stronger than the motor cases! Didn't bead blast it or anything because if I did I would be left with a pile of dust. :)
:)
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So this project might go into hurry up mode and the cosmetic stuff might wait until winter. Once my nephew heard I started getting parts in, he said "Just put it together Uncle Mike, I want to ride!" :-D
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Well since the bolt kit is going to take longer than expected I decided to do some painting. I got the swingarm cleaned, sanded, and painted today. Yes it's just rattle can, yes I know it will scratch and chip easily, no I don't care, ;D . It's going to a 10 year old who is going to beat it I'm sure. I just want it to look nice when he first "officially" gets it.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/Swingarm.jpg)
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Check the run out on that crank, I saw a nightmare you tube on a wiseco crank for a 2001 CR250. They make them in tiwan, could have been a bad one but scince then they make me nervous...
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I'll make sure I do that, thanks! I have used them before but never checked them, but I will from now on.
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I decided since funds are limited I would just apply a healthy dose of elbow grease and clean the cases instead of getting them bead blasted. A wire brush, some Simple Green and then Purple Power when I ran out of SG. They are not perfect, but they look much nicer.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/CleanCases.jpg)
I also painted the ignition and clutch side covers. The clutch side came out like crap, must have missed some oil. So I stripped it down and will re-spray it later or tomorrow.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/IgnitionCover.jpg)
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Looks like its comin along nicely for ya Coop, the cases look really good in the pics..
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You've got more patience than I do Coop. Nice work.
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Starting to look like an engine:
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/clutchcover.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/tranny1jpg.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/bottomend.jpg)
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Engine is done and frame is painted. The cylinder and head are much brighter than the cases, but oh well it's ready to run. The frame is also lighter than I wanted (almost looks like shiny primer), but I couldn't find the shade I wanted in a rattle can. Once the steering stem bearings come in I can start putting it all back together.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/moto_0139.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame2.jpg)
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Sweet!! ;)
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I spent an hour in the garage. I got the engine in, swingarm on, brake assembly installed, electronics hooked up, and checked spark.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame4.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame6.jpg)
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Lookin good,nearly there.......
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I think your nephew is going to put you up for uncle of the year... :D
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Thanks guys. I am in a holding pattern until the steering stem bearings come in. Supposed to be yesterday, now a resheduled delivery date for 7-8. Guess I paid for 3 day select shipping for nothing (it shipped on 6-30) :( .
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I got the stem bearings in, the triples on, disassembled the shock, cleaned it, painted the spring, lubed all the bearings, used the wire wheel on the link, painted the top mount, and got it all put back together. I didn't realize until today, that this bike has an after market shock. It had a Works Performance sticker but I didn't think anything of it until in the manual I realized the stock shock didn't have the reservoir.
The wheels need a lot of love so it may be a couple days before I get back to assembly. Once I get those cleaned up though, it won't be but a couple hours until it's done. I do not care for the purple CEET seat cover or purple/pink/yellow CEET radiator shroud graphics but I am leaving it up to Nick to see and decide if he he wants me to change it.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame7.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame8.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame9.jpg)
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Dare I call you an artist Coop. Lookin good. Man if I had another bike to ride I would like to do the same thing with my KX.
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Thanks. I am trying to make it nice for when I first give it to Nick. I am sure he will trash it quick enough :D . I also slapped the forks and bars on tonight. I don't like the bars, but I am outta cash for this project so they'll have to stay for now, lol. I also want to replace those rusty bolts on the rear link soon. I tried cleaning them up with the wire wheel but didn't have much success.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/frame10.jpg)
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Hey Coop it's starting to look like a bike again...
Just a reminder to you and all of us who love to jump on a 60/65 or 80/85. Have respect for the little bikes. they are a lot faster than you think. I know my last experience on a CR85... I realized after I had it pinned in 6th gear with a fence fast approaching, that the rear brake pedal was tucked under the case, and I could not get my foot on it... After a quick prayer to the MX Gods, I dropped it to 4th, stuck out the boot and excited a perfect 180 wheeling out of the turn... I gave the back back as if nothing happened, but then I promptly had to go change my shorts...
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Thanks for the reminder, but know all about it. I have been riding off-road for 30 years and used to be a mechanic, which seems like another life now since so much has changed for me in the last ten years, LOL.
But this bike is for my nephew, and the quickness of it is one reason I told him he can't ride it until I can get him fully outfitted in gear. We still need to get our hands on some boots, if anyone has some boots a ten year old could wear and want sell reasonably pm me :) . It will be a lot different than the PW50 he was riding. He is very short for his age and just actually outgrew the PW size wise this year.
The fact that Nick is getting this bike is why I am taking it so slow to make sure every part (and I mean every part) was inspected and is in safe working order. I've had to forgo some cosmetic plans I had because I found some things that needed replacing as the work progressed.
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Painted the radiator with aluminum high heat paint, think it looks pretty trick. Mounted the hand controls, throttle and throttle cable, grips (Nick picked green, I wanted black), mounted the radiator, installed the hoses and shroud. I also mounted the rear mud guard and top shock cover. Once I get the pipe I will finish the assembly. A member on kxriders.com is donating a Pro Circuit pipe and silencer to the project so I am waiting for it before I continue. I think the tank and wheels are going to take away from the project some cosmetically. The spokes are really rough and the tank is really dark on the top with faded spots where old graphics used to be. I tried a heat gun, wet sanding, and rubbing compound and none of them did anything at all. I am out of money though so the spokes and tank will have to wait, lol.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/rtside.jpg)
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A member from kxriders.com, ThrottleJunky, is an amazingly generous person! Not only did I get this very nice KX60 Pro Circuit nice pipe and silencer in the mail today, but also a second box with boots and chest protector in it for my nephew as well! I think the gear will be too small, but I am truly blown away by his kindness and help with this project.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/PCpipe.jpg)
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Great job Coop!!
It's looking really good.
I'm always touched by people's generosity and kindness.. please say a thank you from me to this wonderful person.
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Yes there is definitely a bunch of good guys on kxriders.com. Prior to my current ride (KTM), I was on the green machine, and received valuable advice from many on that board. They are a very friendly and knowledgeable group.
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I was really taken back, I didn't expect the pipe to be in such good condition and I didn't expect the gear. I will be sure to pay it forward if it doesn't fit Nick. Keep the generosity flowing :D .
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Thats amazing Coop, that'll make the little KX go very nice. Unbelievable generosity :D
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Starting to look like a bike. Luckily I was able to spin the shock reservoir down to miss the pipe but still also be clear of the shock. I need to figure out something for the silencer mount. If I use the mounting points on the frame and silencer, the silencer just goes into the pipe. If I fully fit the silencer into the pipe, it is about 1.5" too short to reach the frame mount. Maybe a short tab with two holes drilled, think that will be stiff enough? That or bolt it to the frame, but use a short section of heater hose and two clamps to seal the pipe/silencer joint. I also need to get a pipe spring, the one from the stock pipe is too long, it hooks on with no tension, LOL. I think I'd like to find a sticker that says "60" to put where my brother stuck that green/black "KX" sticker. The wheels will be on tonight or tomorrow, then it's just get a couple of perches and it's done. The front tire has some cracks in it, but has been holding air since yesterday. So I am using it for now. I am excited to hear it run. I could start it now, but I want to wait until it's rolling.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/rtside2.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/lftside1.jpg)
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thats gonna look sweet Coop,ya nephews gonna be stoked as!!
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Thanks. I think it will be finished today. I am heading out in a little while to finish cleaning up the rear wheel. Then I will mount the wheels, install the clutch perch (as long as the UPS guy isn't too late), ad gas and oil and try to start it up!
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I would say it's 97% finished. I need to remove a link or two from the chain and install it, adjust the brakes, slap on a clutch perch & lever, tighten the kill switch, polish the PC plate on the pipe like ThrottleJunky suggested, add fluids and that's about it. All small stuff. Once it's "officially" done, I'll use the camera and take some nicer pictures.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/lftside2.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/rtside3.jpg)
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It's done! Started second kick, my nephew Zach is a witness, LOL. Followed the break in warm up and rode it easily around the yard a couple laps. It is very loud! I am going to repack the silencer tomorrow. Clutch cover gasket is also leaking a little and the shifting is sticky, you have to push the shifter down a 1/2" or so and then it will shift up into the next gear. I will have the clutch cover off tomorrow anyway so I will be able to check out the shifter mechanism. Zach insisted on the numbers, I don't like them. But it's not my bike so as long as Nick does it's all good. I have a bunch of stickers here, I am letting Nick decide which ones he wants on it and where. I will be sure to post pictures once he first see's it. Hopefully that's tomorrow.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-6.jpg)
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/KX60-16.jpg)
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Great job Coop!
I'm sure that Zach is stoked and you probably have a hard time scraping him off the ceiling, because he's so excited!
What a wonderful uncle...
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Thanks John! There's quite a few details I wish I had the money to correct, like new cables so I didn't have to use the old ones. They are functional and in good working condition but definitely show their age on the metal parts. I would have really liked to put new bars on it, a decent graphics kit, stuff like that. It didn't turn out bad though considering my low budget. My wire wheel mounted on the drill press got quite a workout that's for sure, haha.
Zach is the 15 year old that lives here with us. I got him a 1997 CR80 Expert earlier this year. Nick is his 10 year old brother and the one getting this 60. But I think Zach was just as excited as I hope Nick will be when it started up. "Two kicks, go Uncle Mike!" he yelled. And then he high fived me. It was fun. Riding has been such a huge part of my life and has given me so much happiness that I try to get my nephews and nieces involved that show an interest in bikes.
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way cool man! i bet that thing will rip once your through with it where are you located i get a pretty good discount through my dealer on motion pro cables i'll see what i can get them for
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Very Cool Coop, Those kids will never forget what you are doing for them 8)
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Thanks guys! I am in SW PA, not far from Pittsburgh.
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Well done Coop, turned out well mate, you should be proud....................what an uncle! ;D
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I was finally able get to Nick up here tonight and I gave him the bike. It will stay here in my garage, because honestly I don't trust my brother not to sell it when he gets broke. Nick loved the bike. At first he couldn't start it, but he got the hang of it. I let him go through my sticker "collection" and he put quite a few on the bike, LOL. No riding tonight, but hopefully soon.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/Nick2.jpg)
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hey coop im originally from pittsburgh. what part of pa? i have been in the army for close to 12 years now but i still go back a few times a year. planning on coming up in august
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I was finally able get to Nick up here tonight and I gave him the bike. It will stay here in my garage, because honestly I don't trust my brother not to sell it when he gets broke. Nick loved the bike. At first he couldn't start it, but he got the hang of it. I let him go through my sticker "collection" and he put quite a few on the bike, LOL. No riding tonight, but hopefully soon.
(http://i47.photobucket.com/albums/f190/SVCoop/Bikes/KX60/Nick2.jpg)
That is one happy young man!!
Great job and awesome that you would do so much for your nephew. Top man Coop!!
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hey coop im originally from pittsburgh. what part of pa? i have been in the army for close to 12 years now but i still go back a few times a year. planning on coming up in august
I am in Acme, PA, about 45-55 minutes SE of Pittsburgh.
Thanks John! He was very excited, it was fun giving it to him last night. I need to find him some boots so we can get out riding. My budget is dried up and I can't afford $100 new ones, so it's taking me awhile finding some. A fellow gave me some size 4's but he couldn't even get his feet in them. I think my sister-in-law said he wears a 5.5 now.
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Oh, and coop, you are a tops uncle :)
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Oh, and coop, you are a tops uncle :)
Thanks man! Nick loves the bike and is very excited to ride it.
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Nick has been busy with church camp and then getting set up in his new school so it gave me some time to get boots. I ordered some Nitro brand MX boots from Ironpony.com for $40. I figured he will outgrow them quickly and I am broke right now so they are the best I could afford. Hopefully if the rain holds off he will finally get to ride this week. I was going to let him ride without them because I am just as excited as he is, but honestly the last couple of weeks he has been one busy 10 year old :D .
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Looks Good!
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You were going to let him ride without them... man, we wasted a hell of a lot of time batting that one back and forth, didn't we?
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Well I only got to that point because I was having such a hard time getting the cash together to get him boots. Even then it was only going to be in the field here by my house. No jumps, woods, etc.
Plus it is having a slight shifting issue where it shifts up into 2nd smoothly, but after that it will only up shift if you push down maybe a half inch on the shifter, sort of "reset" it. I've torn it back apart twice now and nothing is assembled incorrectly and I can't find anything obvious that's worn. I have a new return spring on the way and think that's the culprit because in first you already shifted down to get there so the shifter is returned to where it needs to be already.
But anyway if he can only shift into second I figured he'd be ok. That bike is really fast, but first isn't exactly a power house gear.