Post by Krazeeun on Sept 13, 2003 21:44:14 GMT -5
This is a topic on rebuilding your top end,
Below are pictures along with a walk through of rebuilding your top end on your own.
First off,
Pull everything out, Clean the motor, pipe and carb as much as you can because you do not want any dirt particles to fall into your bottom end uppon dissasembly, Also clean out an area that you'll be working on your quad and lay down a towle below your quad so if any small parts are dropped they wont become lost - it will also give you a clean place to temporarily place parts.
Now start taking off the seat, gas tank, and any other body parts that might cause an obstruction while dissasembleing your top end.
After you remove: The cylinder head, Carb and Reed Cage - It should look something like this:
Cylinder and Head:
Reed Cage:
Its now time to remove your cylinder,
Start by removing your pipe, Base bolts and any other thing that may cause obstruction.
Cylinder:
After doing so, it should look something like this:
As your probly noticed by now - the motor and the other areas around my engine are quite dirty, it was my mistake of not cleaning it before the teardown, please dont make the same mistake. Anyways, you've also probly notice that my piston is quite scared - giving an excellent explanation of why I only had 110 PSI before the dissasembly.
Ok,
Now you've successfully taken apart your top-end.
Get a top end kit, bored and hone the cylinder (if needed) and get the correct size piston and rings.
---------------------------------------------------------------
Alright,
Once you've gotten all your parts back in you can start assembling the motor...But first, here are some steps in doing so. Unfortuneatly I do not have pictures for this part.
Start by removing your old piston and replacing it with the new one, take your 2-stroke oil and use your fingers to aply the oil to your piston pin, rings, piston walls (inside and out) and piston clips. Once you've gotten the new piston on, take the cylinder and coat the walls (using your fingers) with 2-stroke oil. Make sure your piston rings are aligned with the pinholes and in there specific place, (REMEMBER TO APPLY YOUR BASE GASKET) and start CAREFULLY sliding your cylinder over the piston...Be carful not to let the rings pop out of their place. To check and make sure they're aliged with pinholes, you look through your intake ports and see if everything checks.
Once you have the clinder on, you now take your basenuts and in a criss cross pattern you skrew them on to a little past finger tight. Check everything and make sure its all correct, then start tightening - again in a criss cross pattern till you get them very snug, I belive its 15-20FT/LBS to be exact.
Take the cylinder head (REMEMBER TO APPLY YOUR COPPER HEAD GASKET, and slide it over your cylinder. Take your head nuts and skrew them on a little past finger tight. See that everything is right and in its place, then (again) in a criss cross pattern, start tightening your head nuts. Tighten them to 20FT/LBS. Skrew in your spark plug but keep the plug cap dissconnected for now.
Its now time to install your reed cage (REMEBER TO APPLY THE REED CAGE GASKET) and carb. Once you have all those on, take the Pipe and install that ALONG WITH THE GASKET. Your quad should now start to look like a living thing again. If you find any other small things, 'undone', now is the time to connect, or attach them (IE: Plug cap, throttle cable, clutch cable, etc).
Start piecing back together, the body (Tank, plastics, seat, etc). Once everything is back together, WITH GAS IN THE TANK, it is now time to see if you can get the beast running.
If you successfully get your quad running (which shouldnt be too hard) then give your self a pat on the back and head inside for a nice cold drink.
Following all this up, it is crucial to see that you properly break in your motor. There have been many posts on this proceadure in the past so read through those before putting any time on your motor.
Well Fellas' I hope this will help you in rebuilding your motors in the future.
If you guys have any questions on the above, or want to correct/clarrify something - please do so.
Below are pictures along with a walk through of rebuilding your top end on your own.
First off,
Pull everything out, Clean the motor, pipe and carb as much as you can because you do not want any dirt particles to fall into your bottom end uppon dissasembly, Also clean out an area that you'll be working on your quad and lay down a towle below your quad so if any small parts are dropped they wont become lost - it will also give you a clean place to temporarily place parts.
Now start taking off the seat, gas tank, and any other body parts that might cause an obstruction while dissasembleing your top end.
After you remove: The cylinder head, Carb and Reed Cage - It should look something like this:
Cylinder and Head:
Reed Cage:
Its now time to remove your cylinder,
Start by removing your pipe, Base bolts and any other thing that may cause obstruction.
Cylinder:
After doing so, it should look something like this:
As your probly noticed by now - the motor and the other areas around my engine are quite dirty, it was my mistake of not cleaning it before the teardown, please dont make the same mistake. Anyways, you've also probly notice that my piston is quite scared - giving an excellent explanation of why I only had 110 PSI before the dissasembly.
Ok,
Now you've successfully taken apart your top-end.
Get a top end kit, bored and hone the cylinder (if needed) and get the correct size piston and rings.
---------------------------------------------------------------
Alright,
Once you've gotten all your parts back in you can start assembling the motor...But first, here are some steps in doing so. Unfortuneatly I do not have pictures for this part.
Start by removing your old piston and replacing it with the new one, take your 2-stroke oil and use your fingers to aply the oil to your piston pin, rings, piston walls (inside and out) and piston clips. Once you've gotten the new piston on, take the cylinder and coat the walls (using your fingers) with 2-stroke oil. Make sure your piston rings are aligned with the pinholes and in there specific place, (REMEMBER TO APPLY YOUR BASE GASKET) and start CAREFULLY sliding your cylinder over the piston...Be carful not to let the rings pop out of their place. To check and make sure they're aliged with pinholes, you look through your intake ports and see if everything checks.
Once you have the clinder on, you now take your basenuts and in a criss cross pattern you skrew them on to a little past finger tight. Check everything and make sure its all correct, then start tightening - again in a criss cross pattern till you get them very snug, I belive its 15-20FT/LBS to be exact.
Take the cylinder head (REMEMBER TO APPLY YOUR COPPER HEAD GASKET, and slide it over your cylinder. Take your head nuts and skrew them on a little past finger tight. See that everything is right and in its place, then (again) in a criss cross pattern, start tightening your head nuts. Tighten them to 20FT/LBS. Skrew in your spark plug but keep the plug cap dissconnected for now.
Its now time to install your reed cage (REMEBER TO APPLY THE REED CAGE GASKET) and carb. Once you have all those on, take the Pipe and install that ALONG WITH THE GASKET. Your quad should now start to look like a living thing again. If you find any other small things, 'undone', now is the time to connect, or attach them (IE: Plug cap, throttle cable, clutch cable, etc).
Start piecing back together, the body (Tank, plastics, seat, etc). Once everything is back together, WITH GAS IN THE TANK, it is now time to see if you can get the beast running.
If you successfully get your quad running (which shouldnt be too hard) then give your self a pat on the back and head inside for a nice cold drink.
Following all this up, it is crucial to see that you properly break in your motor. There have been many posts on this proceadure in the past so read through those before putting any time on your motor.
Well Fellas' I hope this will help you in rebuilding your motors in the future.
If you guys have any questions on the above, or want to correct/clarrify something - please do so.
