03/16/13 - Decided to table the project until i can save up $4k, and pay off my cc
03/18/13 - Now I'm toying with the idea (will do) of replacing the sleeve myself...oven...and freezer
05/11/13 - Brian stopped by, cleaned the top of the piston off and found that it is a .010...we mic'd it, but couldn't get numbers that were in the proper range
05/14/13 - Bo picked up the cylinder and piston and offered to take them to [THE SHOP] to have them looked at
05/15/13 - Got the information from Bo, from [THE SHOP]. Total parts & labor, est. $350 ($163 .010 piston, $38 gaskets, $70 bore & hone, $65 rebuild power valve (not incl parts))...i went back and forth thinking about why would i use the same size piston that was in there before, AND bore it wider? Talked to the guy, he seemed confident that the clearance was within spec...so i ordered the .010 piston from Amazon ($93)
05/16/13 - Thought about it all night and none of that sat well with me...fortunately, i was able to cancel the $93, .010 piston, and order a $104, .020 piston. I may let [THE SHOP] do the machining, but i'm still not sure yet
05/18/13 - Bo took the parts (he had them the whole time!) to Mountain Motorsports, the guy said the pistion was 67-point-something...he measured it with calipers, though...he recommended the machine shop they take their stuff to
05/23/13 - The piston came today!
05/24/13 - The piston was returned today! After measuring it last night with the micrometer, and comparing the numbers to stock, i figured my math had been wrong...looks like .010" = .25mm, and NOT 1mm, like i was thinking...so the "old" piston was .010, 67.25mm...then the guy at "the shop" was right in that the 68mm piston (.040") would be the next size up, as they no longer make .010, .020 or .030 sized...the 69mm (.080") piston i ordered is prolly "too" big for now, "don't go up unless you have to"...so i packaged it, got the RMA from amazon & did the exchange for the 68mm, and took it to the ups store.
05/25/13 - Bo brought the piston and cylinder back, just measured 'em
06/01/13 - New (68mm) piston came today
06/02/13 - Took the cylinder and piston to "the place" (Rockdale Cycles)...guy said he'd hafta pull the power valve to bore it...he's prolly gonna "fix" it, and charge me for it! I shoulda done it myself first, no pics!!!
06/02/13 - Ordered the kill switch off ebay
06/05/13 - David at Rockdale Cycles called and left a message to call him back...uh-oh...
06/06/13 - Called David at Rockdale Cycles back, he said the LH power valve [the shaft] was broken...said the dealer no longer carries the part...told him I'd look on ebay...I did, and found one! Ordered it ($40)
06/06/13 - Ordered a b*tt load of other parts today, mostly hardware
06/06/13 - The kill switch, number plate, and brake lever came today
06/07/13 - Ordered the chain and rear wheel bearings off ebay
06/08/13 - Installed the kill switch
06/10/13 - The reeds and the power valve came today
06/11/13 - Bo came and picked up the new power valve
06/12/13 - Bo took the new power valve to the repair shop, and took a pic of it compared to the old, broken one!
06/12/13 - Ordered the "top end bearing" today, didn't think I'd need one, but further reading suggested NOT replacing it is NOT a good option!
06/12/13 - David from Rockdale Cycles called, he said it's ready! Total damages, $135, just what he said! ($70 boring & honing, $65 power valve rebuild)...shoulda inspected that power valve before I took it to him like Bo said!
06/12/13 - Rear wheel bearings came (but just noticed I ordered the wrong ones!!! so I just ordered the correct ones).
06/13/13 - Bo brought the parts home, they look good! Took some pics of it, sprayed WD-40 (that I went and got from AutoZone) in the cylinder; Bo said he'd paint it for me
06/14/13 - The chain came today (actually, it probably came yesterday, during the storm)...removed the chain
06/17/13 - The correct rear wheel bearings and the top end bearing came.
06/25/13 - Took the rear wheel off
06/26/13 - Began the rear wheel bearing removal process (you don't hafta remove the brake disc or the driven sprocket, like the manual states)...after hammering on the bearing, found out there IS a snap ring securing the bearing...couldn't find my snap ring pliers...i'll get some tomorrow, and i'll order new snap rings! hope i didn't damage the groove!
06/27/13 - Got the OEM cheap 4-in-1 set from Autozone...it worked to get the snap rings off...got the bearings out...got 5/6 sprocket fasteners off, rung one off (or it was already boogered up)...i'll drill it out tomorrow
06/28/13 - Drilled the bad bolt head off! Sprocket removed!
06/28/13 - Ordered new sprocket mounting hardware, and new snap rings
07/12/13 - My parts gaggle (and the stuff from the last order I placed) (from G & S) FINALLY came today!
07/18/13 - Got the bearings and sprocket installed, and put the wheel on...but i "think" (am pretty sure) the bearings are too tight, as i had no wiggle room for the spacer...so i'm gonna redo it
07/20/13 - Got the blind hole bearing puller from Harbor Freight...got the snap ring pliers from Sears...removed the first bearing (sprocket side) without issue...FORGOT to remove the snap ring on the disc side and that caused all kinda problems, but got it out...ordered a used hub, just for spare parts, and ordered new bearings
07/24/13 - The hub came today
07/25/13 - The wheel bearings came today
07/26/13 - Installed the wheel bearings; loosely put the wheel back on the bike
07/28/13 - Painted the cylinder and exhaust valve cover
07/29/13 - Ordered the chain rivet tool
07/29/13 - Painted the cylinder head and exhaust valve side cover
07/30/13 - Cleaned the cylinder mating surface on the crankcase!
08/01/13 - Installed the exhaust valve cover
08/04/13 - PLANNED to install the cylinder, but got to that step and realized they sent me the WRONG BASE GASKET!!!!
08/07/13 - The CORRECT base gasket came today
08/09/13 - Installed the piston and cylinder
08/10/13 - Cleaned the exhaust flange
08/11/13 - Installed the new reeds...didn't use threadlocker (as i didn't see any on the old screws) and had to ream the holes on one reed to get it to evenly cover the cage; got exhaust screw (will try allen) for the exhaust flange; torqued cylinder, installed cylinder head and exhaust valve actuator rod and cover
08/24/13 - got ratio rite, semi-put exhaust on, put reed valve in
08/25/13 - put carb on, loosely put fuel tank on, "redid" cylinder head bolts (2), put front number plate on, got gas/can, tried cranking, no dice...got a new spark plug (Autolite 4063) from advance, still didn't run; ordered a coil
08/26/13 - pulled and tested the coil, is within specs; bent the bracket in the process; ordered a new one...then another one...then a coil AND bracket; ordered some other parts from cheapcyclesupply.com
08/27/13 - ordered air box lid off ebay!
08/29/13 - all the coil parts came; put the "new" one on...bike still won't run; and i can crank it over by hand...
08/30/13 - the stuff came from cheapcyleparts (mostly air filter stuff, brake lever boot, misc hardware)
08/31/13 - had it running!!!! but idle is WAY too high and still blue smoke, and it took starting fluid to get it going...so i think the crank seals are bad...
09/03/13 - bought most of the vacuum/pressure test hardware from ACE and Advance; ordered the MityVac silverline vac/pressure tester from amazon
09/05/13 - the MityVac came; bo brought back my drill battery
09/06/13 - hooked up the leak test stuff...gauge needle isn't moving AT ALL...major leaks? found a leak at one of the rear screws on the LH crankcase cover, and on the RH cover at the rear mating surface
09/07/13 - got two impact screwdrivers (one for Brian) from HF; "drained" the transmission oil...it was BONE DRY
09/08/13 - inspected that carburetor slide...compared to pics online, looks like slide is not closing fully...disconnected the cable, now it closes fully...cable too short? has it always been? did i install it wrong? began crankcase cover disassembly, drained coolant; removed water pump; removed brake pedal and footpeg; impact screwdriver worked LIKE A CHARM; but cover is STUCK on there...read up, gonna try the finger in the oil filler hole method
09/09/13 - Still couldn't get the cover off...used the plastic scrapers to wedge in there, broke the tips on each one! gonna try and clean all the gasker sealer away from the cover, and clean the kickstart shaft/area and WD-40 it, and try again
09/10/13 - Not only STILL couldn't get the cover off, but broke one of the tabs that is supposed to facilitate in cover removal! Ordered a cover off ebay...gonna pull the engine out, and replace all the bearings and seals...eventually
09/13/13 - Clutch cover came
09/14/13 - Removed flywheel nut (14mm)/lock washer; ordered flywheel puller from Motosport.com ($13.99 + $5 shipping = $18.99);"Won" those engine cases off ebay
09/17/13 - The flywheel puller came..used it, and removed the magneto...would've taken the stator/plate off, but a regular screwdriver ain't gonna cut it...didn't try the impact (yet), but i think the bits are too small...may try the bigger one, or see if that 29-pc. kit from craftsman will have a bigger (#2? #3? ) phillips
09/18/13 - Got the stator/plate off...the "big" impact screwdriver (#3 phillips) from HF worked! Tried pressure testing it, but maybe the loose cover is a major air leak? also, the piston was probably not at BDC anymore
09/19/13 - Got all the engine mount bolts off except the swingarm bolt; and of course the clutch cover NOW was easy to pull off!!!
09/25/13 - JUST ordered air chisel hammer bit from globalindustrial.com, $20.63 total
09/30/13 - the hammer bit came
10/15/13 - bo brought over his air chisel