David Keith

Is there a burr on where the drill went thru? (the inside of your drilled hole?) Be sure there is none... If you do sand the slides, use 400 grit or finer.

Yes, it will be fast when you get the jetting dialed in. What is your jetting right now? How is it running?

That makes sense. The stock keyway is much stronger without a step milled in it.

How did you get 6.4:1 ratio. At sea level, atmospheric pressure is 14.7 psi. & 14.7 times 6.4 = 94.1 lbs. That doesn't sound right... '01 stock should be 8:1, which is about 120 lbs compression. If you mill off 0.025, there will be an increase in compression by about 10 lbs. Just my opinion.

When I've split the cases on my Banshee(s), you could always reassemble the motor & verify that it shifted thru the gears. You want to do this while its' still on the bench. Are you twisting the gear-shafts back & forth to get the teeth to align...

Good advise. We really need to know more.

As long as the surrounding area is not "distorted", it will be fine. It would be a good idea to run a fixed style hone to make sure there are no high spots.

Yes, always unplug the cdi & connect the ground to a bare spot, not a painted area, so that it won't arc while trying to ground...

Yes, 340 would be a good starting size. Better to be just a bit rich as opposed to too lean.

Yamabond will seal better for a longer period of time. Go ahead & try it. If it leaks, then it may need to be re-machined.

Letting the gas set for a month isn't good anyway. That's about how long it takes for the pilot jets to start gumming up with varnish. Even though many gas companies want us to believe there are additives added to stop that. Problem is, the additives just don't keep the fuel fresh that long ...

Sure it will fit. If you change the total overall length by one tooth, then your axle position will only change by half of a link pitch.

Positively one of the best piston products available... They come with wrist pins, circlips & gaskets at no extra cost.

This is right. You need more than 0.020 inches clearance because when you're engine is turning more than 10,000 rpm. The rod stretches, the piston stretches & the crankshaft actually flexs as well. All of this is why engines need more than 0.020 inches of clearance. Talk to some professional builders & they will verify this for you. There is static clearance & dynamic clearance issues involved here. Just imagine what might happen if the piston starts hitting the head...

Sounds like a pressure test is needed. Determine whether or not the engine has a leak. If you have covered the other basics, this is next.

That's right, it is the largest mushroom I have ever found! Eleven inches high by over 4 1/2 inches diameter. My daughter was excited to hold it for me & even happier when my wife fried it & we ate it for supper later. It fed us two complete meals! Excuse me for not responding sooner.

Right on. Better to check for any possible leaks before starting it again. Rubber boots only stretch so far.

You're right. That's what you call "preventative maintenance".

Sounds like you know what kind of "quality" to look for in a bore job. Why don't you take the jugs to a "professional" like "Larry Zumbrum Racing" & get it done right... Then you won't be tearing it back apart after premature wear... Good luck.

When you took the clutch cover off & discovered the loose nut, did you make shure that evereything was lined up & rotating free before using the impact driver? Have you drained & inspected the oil yet?

I haven't seen where anyone has asked about the choke cross-over tube being properly connected. I have worked on more than one Banshee now that had all the symptons described above & the cross-over tube was missing!!!

If you everything cleaned off & it still leaks, why not try some "green slime"? (www.slime.com)

Have you got a manual to verify the chain routing? Remember the direction of the master link clip during reassembly.

No need to be confused. It sounds like you have established that you're compression test gage is okay because it worked fine on another motor. I've seen an engine run with compression as low as 50 psi before. It can happen. You just need o trace down where the leak is. Since it's leaking coolant, it may just be the head gasket. A stock engine should have at least 120 psi because that represents 8 to 1 compression ratio.

Yes, I've got a set of stock carbs for $45. Still in good shape. PM ME if you are interested.