Rebuild Time, Ahh Sigh

[sweetshee4312]

ok, well my compression is off by 20 psi in each cyclander, and im woundering, howd do i do a top end rebuild, what exactly do i need. Is all i have to do it ored the cylanders, and get new pistons slap em in, and im done

[SICK BOY]

Get a Clymer manual,and a top end rebuild kit (you'll have to find out what bore you need).The manual will walk you through it step by step.Take your time,lable everything,and learn.If your cylinders and pistons look good you may only need new rings and a hone.

[Schizo]

Is all i have to do it ored the cylanders, and get new pistons slap em in, and im done

You wont have to get new cylinders unless yours have been bored out so many times that there is nothing left to bore anymore.

[PlaynSand]

Sweet , Just crate up the whole engine , send it to Passion and tell Jim to give you the works.

 

Yes get yourself a manual and follow very carefully and you should be fine , and if you have any questions , post them and we will try to help.

[BansheeBrian]

I just did a comp test on mine and I need a top end too.I have the clymers manual(finally) and i just need money to do it. Right cylinder is shot to shit.The manual is is very precise on what needs to be done.It will be a good expirience.

[MotulMonsta]

You might be able to get a way with a hone and re-ring job. ALOT cheaper.

[sweetshee4312]

ye, i was onna get vitos ss pistons, just for mooooore powwwwer:)

[.]

Take the cylinders off....consists of removing plastic, tank, carbs, and pipes (drain coolant first, dont forget to open up those little bolts on the side of your cylinders). And then pop the cylinders off....might need a rubber mallet to break them loose a little bit.

 

Back the head off from number 10 down to number 1 in 5lb increments to reduce risk of warping the head.

 

Take the cylinders to a machine shop and find out how much they need to be bored out. Get a piston kit (usually 150 bucks shipped from many online and magazine companies, dont go with NBS distributing, formerly Recreation Unlimited, horrible company)

 

Take the cylinders and pistons into the machine shop and have them bore the cylinders to the pistons.

 

Check play in crank (clymers manual or the online pdf on here has specifications), and put the pistons, with rings on, wristpin, wristpin bearings, and circlips back on with arrows correct way, and a rag over the crankcase so you dont drop anything down in there (should have a rag over at all times including taking the pistons off the rods). Throw the cylinders on, torque them down to 20ft lbs. in 5 lb increments, Throw the head on to 20 ft lbs in increments and throw the rest of it back together and you should be good to go.

 

Do a search on proper break in techniques. I use the honda 2 stroke oil thats non synthetic (honda 2r I believe) and run that for about 3 gallons to seat the rings properly and get the most out of the engine, before switching to a synthetic/synthetic blend oil. Do a search on proper break in on here....its been discussed many times.

 

It's easy.....only thing you need is a socket, extension, socket wrench, 12 mm wrench (I believe those are the nuts), a screwdriver and pliers and you should be good....just remember to tighten down your nuts in 5 lb increments to 20 ft lbs and you'll be good to go.....

 

If you have any mechanical skills at all....you dont need a clymer manual to do a top end rebuild.....I think I could do it in my sleep.

 

Total cost when said and done including the oil, and gas will be about 250bucks to get you up and running again....more if you want a vito's kit.