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Hmm what to use as stoppers in the intake and exhaust..

Fun Wheel Drive

Do like they did in the video, rubber expanding freeze plugs.

I didn't actually swap over stators to verify both were good. Got lazy. I'll try that next before removing the engine for testing.

Fun Wheel Drive

New stator is in from a working donor on ebay. Wrenching time!

Fun Wheel Drive

Got the new stator in, wired up and assembled. Fresh(ish) plug and gas, and it started right up! Runs really well. Might need a little tuning, and probably a water pump seal (what else is new),and the stock USD forks are leaking and need guards, and the word silencer needs packing, but it runs!

Even though the old stator had good resistance readings, it must have had a partial short.

So excited! Now I can take off the top end and put in the BDK valves that have been waiting patiently for a home and a purpose.

Fun Wheel Drive

Awesome!!!! Glad to hear it


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COOL!

Tore it apart, cleaned up the cylinder and valves, greased it all up, put the new ones in, looked things over and.... there's a hairline crack in the cylinder in front of the main exhaust valve.
Yeahhhhh so I'm pricing out the repair work, or shopping for a good used cylinder. These bikes are supposed to be old, cheap, and easy to fix!
Pretty sure it needs a new waterpump seal and stuff too.

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450$ later and I've got a new wiseco piston, repaired cylinder with nicasil plate from Millennium Tech. Put it all back together, checked rings gap, etc.
Drained the oil out - slightly milky. Ugh.
Looking for the water pump seal how to thread now..


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A race to the bottom between your patience and your wallet.

Sorry for all the bad luck. At some point, you will have a lot of mechanical areas to not worry about for a long time.

New water pump seals in - and I went ahead and did the bearing while in there.
There was no 2nd seal on it, and no washer behind the impeller. Water pump cover gasket got damaged too. So now I'm waiting for delivery of the gasket and washer. Then it's game on..

I took my 92 dx200 hybrid out yesterday and had a blast. Found a new single-track 10 min from my house. Looks like it's intended for Mt biking, though. Tried really hard to not rough up the jumps that someone clearly out some time and care info.
Very excited to have a buddy bike that I can go goof off with a friend on.

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Game on! Fired right up, warmed up and rings seated about a minute later. Cool feeling!
Thanks for all the input guys. Now that I've done all this, the bike will never need anything else so I guess that's it for this thread. Hehe


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Awesome... Well done Having a buddy bike is great. Mine gets quite frequently


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Hehe. It's 100+° here on a daily basis, so not the most popular sport right now.

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Friedom wrote:Hehe. It's 100+° here on a daily basis, so not the most popular sport right now.

I'll probably be out riding Marana on Sunday even with the heat advisory! Just gotta hit it at 5am!

That's awesome! Let me know next time (a little more advanced notice) and I should be able to join up!
Doesn't get hot till 10 or 11 anyways!

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