Two Stroke Motocross
Two Stroke Motocross Forum => General Two Stroke Talk => Topic started by: Street_Kleaver on June 29, 2011, 03:44:08 AM
-
Picked up this old rocket. Big Plans!
The bike when I picked it up was 1 owner and just been ridden, thats it , but the engine was worked on by a bike mechanic. Still has plenty of compression just general wear and tear and neglect of a bike that age. ie bearings, linkage bushes fork seals etc.
My aim is to build it into 144. The only thing I'll be getting done is the 144 top end. So far I've rebuilt the forks and rear shock and gone through alot of the nuts and bolts that were seized, rounded or torn off which must of been from superman hanging off them with a 1 inch drive socket set. haha
Its a bad phone photo but its the only one I got when I first got it..
Bad black plastics and all! And dodgy stuff everywhere. All the bolts had no anti seize and seemed to be torqued up to "FT" tension (*@#in Tight) as we say.
(http://www.allthingsmoto.com/photopost/watermark.php?file=13782)
Rode it for a while then gave it a freshen up. Flu designs sticker kit and full set of new plastics, FMF fatty and powercore 2 silencer. Not too sold on the graphics, might change them down the track.
Another bad night time dodgy mobile phone picture. Sorry. I didnt even ride it like this...
(http://www.allthingsmoto.com/photopost/watermark.php?file=13783&size=1)
Then I decided to pull it apart.
Used my arms and hands in a sequence of motions. Result was back to bare metal then waved a spray gun around a bit and this happened.
(http://www.allthingsmoto.com/photopost/watermark.php?file=13779&size=1)
New Swingarm linkage bushes and bearings, polished the swing arm and started to bolt it back together.
(http://www.allthingsmoto.com/photopost/watermark.php?file=13781&size=1)
Bottom end is rebuilt.
With new OEM crank, bearings and balance.
Every bearing replaced. Every seal. 5th and 3rd gear dogs were a bit rounded, so they got replaced. Drive shaft collar, Crank collar. New gear selector drum segment. Drum stopper from a 02, has a better design. All new springs on p/v gov, shift shaft, shift stopper... New clutch plates, steels/fibres and springs along with the billet clutch basket. The list goes on. Everything will be tight and operating like new in there like its just rolled off the showroom floor.
The 144cc top end is being built and should be shipped shortly. Its a bored to 144cc and re-plated 02 cylinder. Ported/polished and high compression head. All done by Harris Performance in Texas.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Bikes/Bottom_End.jpg)
Installed a divider plate into the Mikuni TMX 38 I'll be running instead of the TMX 36. Cost me $8.60 for a length of 1.6mm alloy. And about 3 hours of fiddling around. Works the same as a "Power now" insert except its on the straight bore side of the carb instead of the bell end. I made a jig with and straight edge and stopper for length, used a fine tooth hacksaw blade and some fine needle files. It was a nice fit, tapped in with a hammer. And a little bit of epoxy (devcon plastic steel) for extra safety.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Bikes/Divider_TMX_38.jpg)
Hopefully it works well with this. Boyesen RAD valve. Nice bit of gear.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Bikes/Rad_Valve_Inside.jpg)
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Bikes/Rad_Valve.jpg)
My aim in this is to try get low rpm air speed increase for a bit more bottom & response and maybe torque. TMX carbs are not strong in the low rpm air signal department.
New ASI Aluminium Radiators. 40% larger. Dual cores. Should keep the little monster cooler. I'll be making my own aluminum radiator braces that has all the mounts built in to run a 05 yz gas tank.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Bikes/Asi_Radiators.jpg)
So pretty much I'm waiting on the top end to arrive from Harris Performance. Suspension to be finished getting re-valved. Suspension tuner is still waiting for parts to come in for the forks and shock.
Once the motor is tuned and run in...
I have a friends stock 02 yz125 to run a comparison to my heavily modded 99 yz144 on the Dyno.
Should be interesting! Stay Tuned!
Cheers
Street Kleaver
-
Nice read, looks like a great project.
Very keen to see dyno numbers compared to the stocker
-
Looks great :) .
-
Very nice! Let us know how those ASI rads fit. I was going to get some for our project, just heard some bad things about fitment.
Welcome to the forum! :)
-
Very interesting project.I've been looking into 125 big bores and apparently 153 and 167 kits are available as well.I'm thinking of building a Husqvarna 125 WR big bore. ;D
-
Badness! Those YZs for that year are some of the best. I used to have a 99 and it was a monster. That bike would haul as-!
-
Nice work.
And welcome.
-
very cool read! I love the white plates and rear fender! Very cool look, and I love the white frame
-
Sweet build.Keep us updated.The 99's were a good bike.I almost bought my nephews when he sold it-but already had the 250.
Sachs,the tuners all tell you if you move much over a 144 you lose a lot of rpm-more of a mid range only machine-big hit and a short duration.
-
That is true. A 125 idealistically should only be done bore only when going for a big bore kit. When they are stroked they loose their characteristics as a 125. Loose high rpm pretty much feel like a 200 instead of riding a screaming 11,000 rpm 125.
Very nice! Let us know how those ASI rads fit. I was going to get some for our project, just heard some bad things about fitment.
Welcome to the forum! :)
From measuring them all up Length and height are identical. Just wider and more rows of cores. I haven't tried a bolt up yet. But they are great quality. The welds are nice, everything is straight and square and all the fittings and mount holes are in the correct position. I have used them before on a friend of mine CR500 engine in a crf450 frame. They were ASI crf450 radiators, but got all the fittings Tigged on to suit the cr500 engnie.
I'll be making radiator cages for each out of aluminium. With side impact and twist protection along with extra brackets that allows a modern 02 yz tank to be bolted up to make people more confused what model it is.
-
Hello all!
Built some radiator cages to fit the ASI radiators. They are a nice fit, look great. Bit tight on one side, but the rubber bushes have give in them so it all works out sweet.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/cages.jpg)
Fitted 05 Tank. Shrouds are off a mates bike. Currently getting some custom graphics designed.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/05tank.jpg)
I made my own ally brackets to adapt the tank in all the original bolt points, the radiator cages now have tabs tig welded on to suit the newer style shrouds. More better pics to come, I'll do a thread up with bracket dimensions so you can make your own out of aluminium.
Waiting for the topend to arrive. I'll ride it, run it in and tune it.
Once its all running sweet. I'll bust the suspension apart to re-valve it myself. Trying to find some info on the suspension stock stack specs.
-
Looks good. I like the white frame
-
Some better pictures
Also made my own brackets for a 05 fuel tank to fit. Tutorial on how to do it is in the technical section. I think Charles has also put it in the how to / Tech DIY section on the site too.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/S6001401.jpg)
Brackets are made out of 40x40 3mm aluminium angle with bushes the same used on the radiators.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/S6001405.jpg)
TIG welded some extra tabs on the radiator cages to adapt the newer model radiator shrouds.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/S6001399.jpg)
Discard the DC graphics. I borrowed the shrouds from a mate. I have some custom graphics coming with new shrouds.
I made a post on here with all the dimensions I used to fit the 05 tank.
Enjoy!
-
More of an Update.
My 144 top end from Harris Performance in Texas has arrived. Its a 02 cylinder and head. Its all installed but the only things that differ on the cylinder is the little springs that pull the exhaust valves open. So I didn't get to fire it over! Grrr. Few more days and they'll be here.
My revalve kit from Smart Performance in California is in transit also. It will bring the suspension into this century. A lot of internal components are sacked out due to the bike being 11 years old. So I cant wait to throw a leg over and give it a ride once I finish the install.
I'll do a in depth install on the forks, much like the tank conversion. For all those guys that like to do it themselves.
It will be like a average guy's factory race bike.
More pics and information to come. Stay tuned!
-
Awesome, you did a great job on this bike.
-
Sweet :D
-
making us aussies proud with that effort.
awesome :D
-
Its ALIVE! :thumbsup:
Big bore 144 topend from Harris Performance did an amazing job on the cylinder porting and head re-design.. Can't wait to ride it!
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/S6001418.jpg)
So far I've done 2 heat cycles. Just waiting on suspension components to arrive so I can finish re-valving the forks.
It's like waiting for christmas to arrive! :)
-
Also did another pretty-up. I documented it for all those guys out there that like modding stuff like me!
This dyeing technique can be used on fuel tanks, So I had a go on the ignition cover and Chain Guard also. Since I can't afford a trick looking Boyesen cover. Haha ;)
It was hard to track down, but I found it! RIT Dye. Its supplied here in Australia in a big craft store called "Lincraft". Its like the mega-store for old lady knitting and craft crap. Goes for about $7 a box here. I used 2 boxes to make sure it did the job. For the US guys its at Wallmart for like $1.50. Which is not fair at all! Haha
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/S6001410.jpg)
About 2 liters in a pot, Boiled it up and added the parts to be dyed.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/S6001411.jpg)
I used my little camp bbq gas cooker. It gives off a pretty strong smell when its boiling, so best do it when "the boss" aint home. ::). Had the parts on boil for about 20mins then let it simmer to a light bubble for a further 40min to make sure it took to the plastic well. Kept stirring every 5 mins. Keeping the dye circulated.
Before Chain Guide (Ignition cover also was a off cream/grey colour)
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/S6001412.jpg)
After. Top Half is after cooling and dry, leaves a salt residue matt finish. Bottom half is with some silicon spray. I used Aussie Export Tyre shine. Its great on plastics, cheap too. Even better, use silicon spray.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/S6001415.jpg)
Installed on the bike. Looks trick. Poor mans factory ignition cover!
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/S6001417.jpg)
Still waiting on suspension re-valve gear. Things are a bit slow with the post at the moment. Hoping I get them this week.
Enjoy!
-
Beautiful! Top job mate that looks sweet :D
-
Very nice! I was going to dye the tank on a KX60 I built for my nephew and then I sold the bike before I did. your parts look great.
-
Finally all done!!
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/yz018.jpg)
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/yz032.jpg)
Before and After. 1 year later.
(http://i1084.photobucket.com/albums/j410/St_Kleaver/Mods/Ragstoriches.jpg)
Massive huge thanks to...
Derek Harris at Harris Perfomance from Texas for hooking me up with the 144 top end.
Dave Johnson at Smart Performance from California for the suspension components and re-valve kit.
NineTwo Decals in Queensland Australia for the Decals
MxRaceprep in Queensland Australia for shims and some fork tube and damping rod prep.
and anyone I have inspired along the way.
Test ride tomorrow to run it in, tune it and get the suspension dialed.
:D
Thanks guys!
-
Awesome!
-
I saw this on FB man it drove me crazy :-*
-
You really did a great job on this bike! ;)
-
Ok. What the heck is up with people posting so much porn on here?!
-
(http://rlv.zcache.com/well_done_stickers-p217818225448435620q0ou_400.jpg)
-
Just one question, seat wise. Are you shorter? Looks like the seat has been cut.
-
Thanks for all the props guys.
The seat is a SDG standard replacement. I'm 6ft, Seems ok to me.
-
That's cool. Just from experience, I can say that newer bikes have a flatter feeling. So you can move front to back better etc. If you have a chance, just look at some newer bikes from the side and you will see. But if it works for you, that is all that matters. Good job on it.
-
That's cool. Just from experience, I can say that newer bikes have a flatter feeling. So you can move front to back better etc. If you have a chance, just look at some newer bikes from the side and you will see. But if it works for you, that is all that matters. Good job on it.
This. You want a flatter seat it promotes better body English. I need a flat seat for my 03
-
The SDG 'Tall' seats flatten out the top of older bikes pretty well.
-
I had a 06 Husky 250. They have seats like ironing boards. Super flat.
But I rode this yesterday. Was really easy to get move around on. I'll do a report soon. :)
-
Seriously??? You're gonna make us wait? I hex you! :D ;D :P
-
Took it for a brief ride on friday.
The thing hauls!!
Rips really hard!!
The sound it makes is so crisp.
Made the switch from using Motul 800 from the last 8 years to using Maxima 927 castor. Man I love that smell!!!
Its not quite jetted properly yet. I got the jetting ball park close. Just needs fine tuning. The combustion chamber is cnc re-designed to run race gas and avgas. At the moment its running 2 base gaskets at 1.2mm squish. With 1 gasket it will be 0.7mm. So once its all run in and running sweet, I'll run one base gasket and some race fuel :D
For the suspension. Its running the Smart Performance Inc full revalve in the forks. SPI developed a new design of mid valve for these old open bath forks called the "Dell Taco". Its basically hydraulic crossover blow off. It works a little differently, takes some getting used to. The fork tends sit up higher in the stroke. Once I started pushing it, it soaked things up pretty nicely. Very plush. A heap better than the stock fork. Although the test track was pretty basic. I was mainly there to run it in and get the jetting somewhat close.
But the handling...
This old bike turns amazingly well!! What i was riding on was red soil hard pack. Keep in mind I've been off the bike for about 8 months. But I felt so confident pitching the thing right over in berms and ruts. Felt like you could charge fast into a corner, brake late, flick it over and hold it on! Was one of the most confidence inspiring bikes I have ever ridden in flat turns, ruts, berms what ever it may be!!
The shock i was running my own shim arrangement from some input of local tuners for our tracks. So far it is working well. Not kicking or swapping. Squatting under power and hooking up. Lifting the front wheel on turn exits. The jumps were pretty small, i did a few harder landings, didn't jar or bottom. Soaked up things well.
I really need to ride it somewhere with some rough sections and decent jumps and hits to really see how it performs. But apart from all that. I was impressed. It gave me confidence in turns and feels stable over jumps. Its a really fun bike to ride. Cant wait to give a good go on some real mx tracks.
Next on the list is some black rims.
I want to replace them with some wave rotors. The brakes are pretty worn, they suck. Haha
I've got my eye on Tusk typhoon rotors for the front and rear.
I'm looking at getting some Black DNA or Black Gforce rim sets.
Or I might re-lace the stock hubs with new spokes with black excels rims.
Haven't decided yet.
This wont be for a few weeks. We are moving town at the moment.
Thanks for all the comments. Keep smoking!
-
Glad you are liking it so far!
-
Awesome job on the little YZ there mate looks really nice, i reckon blue rims would look cool