125-200cc 144 kit install pix and reference info

thanks for all the pics and info kelly!

the red head is the sexy !

Seems a bit of a lottery. Mine came with 0.5mm

I really appreciate your help on laying this out with pictures and all. I'm just doing mine so very helpfull. I can't seem to get this pin out that holds the power valve rod. Any advice?

The pin does not come out. Rotate the PV rod to get it out of the old cylinder.

Thanks Rancher, No issue getting the PV rod out. I just decided to make my own retaining pin for the 144 kit. Cheers!

Just finished (kind of) doing my 144 swap. As a first timer doing a top end on a 2 stroke I thought I would share my experience/mistakes...

What came with the kit
-head
-cylinder
-piston
-ring
-wrist pin
-C clips
-2 head O rings
-Base gasket..not sure which one, I forgot to measure it.
-power valves
-power valve rod retainer pin (more on that later)

What didn't
-coolant drain plug crush washer (1 aluminum washer)
-head crush washer (5 copper washers)
-Power Valve cover gasket
-needle bearings

What lacks in most of the "how to" links was the steps leading up to the swap.
1.drain the coolant,remove hoses
2.removal of the power valve linkage side cover (3 bolts),disconnect linkage at bolt (1 bolt)/remove inner cover (1 bolt)

3.remove the head (5 bolts)
4.remove the cylinder (4 nuts)
5.remove the C clip, slide pin out and remove piston and needle bearings

So the cylinder is off and Im swaping the power valves. I didn't remove the gasket since Im not re-using it...that's were I missed the pin! On the right side the you can see the hole where it goes between the two right threaded holes. (wish I knew how to do all that fancy PaintShopPro stuff with arrows and circles)

144cc kit on the left, 125cc on the right.



Valves were the scariest part for me, and really kind of self explanatory once you get into it.

I am really disappointed I have to wait another week or two for the gasket and get it installed.

I go to put the C clip in the new piston and notice there is no recess on the right side of the piston to install the C clip...WTF?

0
I installed the C clip on this side first (right side)

Putting everything back in reverse (use 2T oil on everything) went smooth except for the PowerValve cover gasket (torn in the pic)


Torque the cylinder,head,engine mount,refill coolant.

Let you know when I get the gasket if it runs

Make a gasket it will take way less then a week or two you can get sheets of gasket material at auto parts store or buy a twelve pack and drink while you use the box to make a gasket lol

What are you torquing the head nuts and cylinder nuts to? For the 125 it states 13-14.5 ft/lb. Is it a bit more for the 144?

If anyone is looking to purchase one of these 144cc big bore kits I have 2 of them for sale in the classified section. They are brand new in the box. Contact me: john@pmconcepts-ny.com

same thing for 125-144-165, I just do 15 ft lbs but either way your good to go

How did you get this pin out of the cylinder? Mine seems to be pressed in there. Any tips?