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#91
Been a while since I gave everyone an update.

Logic says that if you get a new crankshaft, the old one has to come out.
I scored a crazy deal on a Tusk crankcase splitter and crank puller.
They arrived yesterday so I set to work.
The case came apart easier than expected.
BBEBA1A9-B814-4B3C-AE4A-AB3DBCE199EE.jpeg 6C24BD3C-0ED4-48C7-9F4B-9D23368B11A7.jpeg 5A6A77A7-6FDE-4395-96A8-68B4C35E78B1.jpeg

The crankshaft is completely trashed. There’s about 1/16” vertical play in the big end bearing.
3BAD543C-D808-412A-9D15-CF98A9A2D586.jpeg 8C877EA5-C708-4483-86BC-07C86DEBA33E.jpeg

Because of the fretting where the bearing goes, I suspect the main bearings spun in the case and on the crank.
761DBA5C-2FB5-4084-B969-B5534A1F9D99.jpeg 9F36DA1C-8D09-4DB0-A1CA-A6F649D5DB0A.jpeg 668AF024-15BB-4E67-86D1-1075343BB10F.jpeg ADE510A8-18A7-43B2-9139-E3C46B418D2C.jpeg 9F36DA1C-8D09-4DB0-A1CA-A6F649D5DB0A.jpeg DBB99A71-F239-4AE3-9163-94671DEE1242.jpeg

I ordered new OEM bearings and seals today. And picked up a hardware kit to replace some of the missing or mangled fasteners.

Frame is ready for blasting. Just need to get it there.

I’m thoroughly enjoying this process. My partner said that she expects I will build another bike :-)
 

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#92
Well I’m a happy camper.

I wanted to get rid of the existing rear brake remote reservoir so I bought a complete 2004 rear brake assembly including new pads.

I didn’t know if the caliper carrier would fit the swing arm but thought if it didn’t at least I’d also get new pads.
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Turns out it fits perfectly.
 
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#95
That's good news ... info like that is also helpful for others, thanks again for sharing. I'm really enjoying the progress reports, makes me want to go out and find a basketcase for a winter project. I say "winter" project, that's when the garage isn't 105 degrees :p

IMHO, the trick to fully enjoying projects like this is to take your time; don't put a deadline on it and enjoy the process. To thoroughly go thru a bike to completion is a big project and would be super rewarding. We're looking forward to the next update!
 
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#96
Thanks @Okiewan, it's been an interesting experience.
It's my first time inside a two-stroke so there's a lot of learning just in that.
What I'm finding particularly satisfying are the nice surprises in dismantling and cleaning. I was expecting the suspension linkages to be just a bear, rusted etc. In fact they are in beautiful condition, fully greased and smooth.
Not at all what I expected.

With any luck my Vertex piston will arrive today!
 
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#97
Cross hatching on the cylinder looks to be in very good shape. To really know for sure you need to get a hold of some proper measuring tools and check piston to cylinder wall clearance with the piston you plan to use, and you'll need to check cylinder taper as well. This will require a micrometer to measure the piston skirt and a bore gauge to check the rest. Most good shops will be able to do these measurements for you if you don't have the proper tools.
 
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#99
Took some time to clean parts so I can have a rolling chassis after the motor is built.

Rear wheel got a good going over.
Hubs look good, rims have some light corrosion, spokes look awful.
The spoke hole closest to the camera by the rim lock is quite enlarged. Not sure what to make of that.
FA518087-FAC9-4A5E-9B04-333956F06CDA.jpeg C5C1F6EF-8C5D-468C-9407-A4DA99FEC0D7.jpeg

Made short work of the swing arm with a brass brush and a Scotchbrite pad.
C6B529AD-DB15-4B51-8FF1-2654F988BE48.jpeg 91E796A9-3A6F-440D-A857-0B0AFD3F98C0.jpeg 2B23AB57-1789-4D4F-89D5-B430983572C2.jpeg

I also rebuilt the linkages but I don’t have pics as my hands were beyond greasy!
 
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I had a couple waddled out holes in my rims on my CRF450 back in 2003. I tried rebuilding with a new wheel and spokes but did more harm than good b/c I am not good at truing things up. Buying a new wheel is expensive.

If it seats tight in the waddled out hole and doesn't look like there will be any issue popping the tube I would run it for now and stay on the look out for a cheap wheel or rim that can be re-laced. I don't think it is anything you need to be in a hurry on.

We love project bikes. Okie may have a link to the DRN Internet Build project bike that has more detail of things. Back in the day we did a lot of cool things. That one was more from AJ Wagoner who is a genius with bike builds.

The only cool thing I really did was a bike bag test: Dirt-bike-gear.com Fender Bag

Following this thread brings back good memories of the good 'ol days of DRN.

Ivan
 
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That link is to a whole section of the forum, with a lot of posts about the build. This post is a pretty good start, at the very beginning of the whole thing: DR Mag: The Build off.... TIME SENSITIVE: Bike Choice Complete.

I really enjoyed re-reading all of that... good times! A LOT of pressure to knock-out a One-off bike, but we pulled it off.
 

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