125-200cc 06 Wr125 Redo - Done

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This is one project that I hate to do on a two stroke. It is cleaning/polishing/getting the silencer ready for repacking.

It had an FMF Turbine Core II on it. So, a little bit of elbow grease should bring it back, good as new!

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Here is the pile of spooge I scraped out of it, from inside. It was clogged so bad that it had a pinky size hole to let the exhaust go thru. It had to been holding the bike back.

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My can of carb/parts cleaner is no match for this. I remember Wally Bean giving me a tip about burning spooge out of pipes. So, why not silencers? I used my propane torch and heated all the parts till it burned the spooge dry. After I was done, I used a small wire brush/my wire wheel on the grinder. It came off just like chalk. It really worked great and saved me that gooey mess! Good Tip!

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After I sanded the main aluminum body of the silencer to 600 grit. I used my DA sander with a 3M 1500 grit disc. Then I put on a 3M wet sand TRIZAC pad (3000 grit) that I use for automotive clear coat. I then took it over and polished it on my buffing wheel. I did the other stainless steel parts as well.

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Here is the silencer cleaned, polished and ready for repacking. My wife said that I smelled like oil when I walked in the house, I said no, burnt spooge. She gave me a funny look!

Oh yeah. That's the only way to do a silencer. "Carbonize" everything with a torch and wire brush it off. Your pipe is probable full, too.

Are you actually going to ride this master piece when it's done?

Yep, Darin you need to burn the pipe too. You will need to use a torch with cutting end on it so you can get the head pipe cherry red and once it is lit then use only the oxygen to get it to continously burn to the stinger.

I sure am glad about the tip because I don't know how I'd get that mess cleaned up. The pipe has to be full too. MOTORHEAD, Evan has no choice but to ride it because we sold his other bike, or he pits for dad. We could take and bolt Walt's 167 on it and ship it to Italy, so they might get the picture we want a 200/Cr Ignition? It gives me something to do up here in Iceland, Illinois.

PS: MOTORHEAD, I think it was you that told me a couples years back to put radiators in the dishwasher? To get rid of the stains. I presoaked them in the sink and then put them in the dishwasher under the pot scrubber mode. They look almost like new! Another great tip!

Thanx Walt, I will do that. Looks like that's next weekend. How much air PSI do I pump in the pipe to heat the dents out? I'll get some freeze plugs and put an air valve in one. Any detailed instructions on tackling this are helpful?

PS: Sure glad I found this CH site and all you guys/gals! I sure have learned some great stuff from everyone!

Darin,

I use 50 psi but have heard that you can go as low as 35 psi.

Here is a sneek peek! Looks like the engine may go in this weekend!

PIC 001 I went ahead and cleaned my center cases using kerosene and kept blowing them out with air. I also pre oiled all my bearings before they spin.

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Next I soaked the new main bearings in Amsoil 2 stroke oil & then pressed them into the cases. I always use care to press only on the outer bearing case.

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I then soaked the crank in Amsoil 2 stroke oil. I went ahead and put a new rod in.

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Next I slide the crank into the main bearing on the flywheel side. I don't like pressing cranks into the bearings, so I made a crank puller out of PVC pipe to pull the crank into the bearing until it seats. I cut the PVC pipe long enough for a thick washer, so my Flywheel nut (when tightened) pulls the crank into the bearing and seats it without damage. You can buy crank pullers but they cost about $70.

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Next I soaked my transmission in oil and re installed it. Well, I went to take the center gasket out of the husky plastic and cardboard sheet and tore it. Bummer! Looks like I won't be able to get the engine done and in the bike till next weekend.

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After the torn center case gasket, I went ahead and moved back to the chassis. I mounted the new Motoz Tires, new black air box, mud flap and subframe.

I also got the silencer repacked and installed, the rear fender and some decals. I had to make the swing arm decals since they are on back, back, back, back order.

I also must have gotten some air in the front master cylinder, because I had to bleed the front brake.

We just got done a little while ago with the pipe. Thanx to Wally Bean's tips, we now have a nice dent free Dyno Port pipe. We also got it ready for painting next weekend. My goal next weekend, is to get the engine assembled, bolted in the frame and firing it.

That thing is really going to be nice. Great job.

too bad you have to ride it - unbelievable work

Darin,

Bike is coming out sweet!