Must...dualsport....let the rebuld begin!

[david]

By the butterfly I mean the flap that opens up where the carb fits into the boot.

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You're going to need to post a picture of the this....I have no clue what you're talking about.

[Tedh98]

I think he is referring to a carb that uses a butterfly or rotating plate to control air flow.

KDXs as well as most dirt bikes use carbs that have slides.

[gabegarcia]

Crap, I forgot that dirt bikes didn't have slides! Ive moved to motorcycles so got them mixed haha

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[Tyl3r]

Yea, I figured you were referring to something else lol

I got two photos of the bike while it was running, before it crapped out on me! Figured I'd share.





Working on getting the motor out. Started on it last night, then people stopped by the garage and I ended up drinking some beers and socializing.

[Julien D]

You gotta get the people that stop by to help. You know, drink beers and tear a bike down. That's what it's really all about.

[Tyl3r]

O yea, I agree! That does happen quite often, I was just disgusted at the time lol

I got the motor out last night and pulled the head. I was cringing because when I pulled the pipe out of the cylinder, a bunch of little metal chunks fell out. Here is what I found:







I am hoping the cylinder can be weld repaired. One side has a good chunk taken out, the other side opposite of it has a bit of a nick in it too but not as bad. I am guessing that a bottom end rebuild is in order also.. I'm sure those metal pieces found their way down there.

Any guesses as to what caused the failure at this point?

[Tedh98]

Unless there is a lot of carbon covering up the numbers on a Wiseco, I am guessing that is a cast piston that broke.

[Tyl3r]

It has the circular machining marks in the top of it as well as an enscribed "C" and an arrow. I can't remember exactly, but I think those were the same scribings on Wiseco that I just put into the other bike, the arrow for sure.

[Tedh98]

A Wiseco should have a series of numbers and a few letters on the top that identify that piston.


A simple "c" on the top would be a cast piston.

[IDRIDR]

Kinda like this stock piston out of my 220?

[Tyl3r]

Yeap... took someone's word for it, and never should have...even after several warnings to still check it. My own dumb fault.

That's a stocker that came apart alright.

[royadams]

Ouch !!!!!

[Julien D]

Ouch, that hurts. That cylinder will have to be repaired and re-plated, and you're gonna want to split the bottom and and clean all that out. Might as well do a rod kit and crank bearings / seals while you're at it.

[Tedh98]

Self inflicted pain always hurts just a little more. . .

Taking a positive outlook on this, now you can rebuild it all and have an engine that is better than the day it was sitting on the showroom floor and will last 20 years.

[KDXGarage]

Without seeing the piston outside the cylinder, I would look at a ring or ring guide pin catching the port edge.

Sorry for your troubles.

[TheGriz]

Man, what a bummer. Good luck with your rebuild.

[Tyl3r]

yupp, the stock one came apart....came apart good too lol





Then I started pulling apart the KIPS...

could barely pull the main valve out because it was all so gunked up


pieces of cylinder came out with the sub valves


lots of caca in there


Does it look like anything is wrong with the head? I feel like the one on the other bike was a lot smoother

It's safe to say this thing was not happy when it was running haha This top end that the guy told me had about 10 hours on a top end was slightly worse than the top end that the guy said hadn't been touched in 10 years (which it had a stock piston too, just found it in the garage lol)

I think I'm going to send the cylinder out for weld repair and replate. There really didn't look to be any further damage than what was shown in the earlier post. For the bottom end, I'll have it taken apart and gone through by a friend's grandfather who has a bike repair shop. What other kind of stuff should I just automatically have him replace since its apart besides the crank bearings? Water pump seal? Anything else?

I was thinking the same about the reliability after the rebuild. I won't have to worry about if its ok or not anymore also which will make me feel a lot better.

[Julien D]

The head looks pretty hosed. Maybe shoot it off to RB and see if he can repair it and do his magic 220 head mod? The bottom end, while it's open, do all the bearings and all the seals. Everything else will probably be just fine.

[thirdgenlxi]

Daaang man that sucks! Especially when it's from somebody not being honest. But, as was mentioned, at least now you can build it up the way you want it. Just sucks it happened so soon right after you got it. Hopefully you can get her back to going here soon!

Even though mine is a 200 and still runs like a dream, I'm thinking I may want to put a piston in it here before too long..... juuuuuust to be on the safe side. It is getting "a few" hours on it, lol

[Tyl3r]

Yea it sucks, but o well. You are right, I can built it as I want and will know that it will be reliable (peace of mind goes a long way for me!).

It looks like the truck needs new tires before winter, so I guess that expense is taking priority over rebuilding this motor right now. Look like I'll be doing the rebuild over the winter to be ready for the 2017 season. I am thinking at the same time I'll swap the front end out with some USD's (forks on it now are in pretty rough shape).

Really on the fence about powder coating the frame and swingarm... I guess I'll have to see how busy I am when the time comes. I did buy some Kawi green powder and tested it out. It is a dead nuts match to the frame and plastic... really want to do more with it!

The wheels need trued also... Wondering if I should say screw it, tear em apart, powder coat the hub and rim, and reassemble with new spokes.

I dunno, I don't want this to end up going overboard like the hybrid did haha, but the potential is definitely there... new plastics, mx rear fender, change all the lights over to LED's, mount the plate under the fender, new hand guards and move the turn signals up to them, highwaydirtbikes.com dash, pro circuit or fatty pipe....