Here's what she was when I started:



Beater drug from beneath literally tons of garbage and earth. As is here wheels are locked and the engine is siezed.  I attacked them today.

I started first by draining the crankcase.  I got out about half a quart of oil and about three of water...nice clean looking water, too...none of that tepid store-bought crap.

I moved on to pull the spark plug so I could fill the combustion chamber with diesel.  There was something rather peculiar about this head, though.  It has another hole opposite the sparkplug with sparkplug threading.  Is this supposed to be a dual-plug head?



After I filled the cylinder I stared taking the pegs, kick-start, and shift lever off.  I was VERY relieved to have all the bolts and brackets break free really easily, despite being frozen up for whoever knows how long.  I did have a hard time with the rear brake, though, but after oiling it up for twenty mintes it set free.  I had the most trouble with the kickstart lever...the bolt had been put in backwards and it wouldn't clear the clutch cover.  I messed up the threads and some of the splines on the shaft to get it all apart.

Then I pulled the side covers.  Again was impressed with the fasteners...they let free just right and worked perfectly despite being flat screwheads.  It was simple work.  Inside it was amazing to see that not everything was coated in horrid rust considering the amount of water I pulled from the case!





I coated everything with WD40 and went to work on the magneto side.  Put a wrench to her and forced it to move just a teeny bit.  Then back.  Then forth.  And so on...until it moved freely.  I was worried that the rings may have frozen to the cylinder walls but the piston moves pretty cleanly.  It must have been something in the case.  Now she turnes over real fast and steady and it blows my thumb out with painful force if I try and cover the sparkplug hole.  With this kind of compression I figure she's got to be able to put around 20hp.  Also, to my suprise, she has really strong fire!  If I had fuel I'd have been able to fire her up!

After freeing the motor up I again filled the case with diesel and put the sides back on...I've got to come back and seal them but there's work yet to be done to the block.  I then focused on teh wheels.  They were much simpler...after a liberal coating of wd40 and dragging the bike around the parking lot for 10 mminutes they broke free and spin real nice.  Now I got to price tires for it, though, which I'm not thrilled about (I hate buying tires).

I'll be working on something else tomorrow, but I don't know what, yet.

pics may not work...trying to figure out why...

I went here http://www.photoartclub.net/projectbike/ and clicked all the pictures individually to look at them, then they showed up when i went back to the thread

yeah it was just a temp glitch..they'll work now I'm sure.

aye mak theyre workin btw it very well might be a dual plug head 

I wonder how i would make that work again...could I just take any dual output coil and slap it on there?  I've got a few of them.

The wiring on this bike is so hacked...bleh...

Yeap probably a dual plug head or possibly a hole for a compression release.Most of the Suzuki dual sports back in the day Had Dual Plug Holes.They usually had a Blockoff plug to go in its Place.I wouldn't worry with Dual Plugs or a dual wire Coil.I would just install a Spare plug in it and leave it at that.

70's logic....if the plug fouled.... just switch the cap to the other plug and keep on riding........ 70's logic

Yeap What Ken said.

heh...if firing two plugs at the same time won't make any difference then I'll probably just stick the bolt back in there.

I got her to fire off a second ago...nice little pop from the exhaust and that skunkish 2-smoke smell...heavenly aroma.  I'll get her propperly oiled up tomorrow, clean the carb, and she'll be runable by evening.

Is that a Bing Carb? or Del orto?From the Bolt on the Top Cover it looks kinda Like a Bing.

I'm pretty sure it's Del Orto...I'm about to tear it apart.

I never heard of bing...

Quote from: makenzie71 on February 19, 2007, 09:16:45 PM
I never heard of bing...

He's thinking of cherries.

Bings are German Carbs.They were used on Maico's.I think they were Used on Canams for a While.I know they still sell them for Rotax Ultralights.y Old CZ used a Jikov AKA "Jack Off" Carb they had a tickle button that you played with until they Squirted.

It's a Del Orto...but it has a critter living in it so tomorrow it'll be a Mikuni hahaha

That's badass man, nothing better than breathing life into a once dead engine, keep us updated with the pics too.

This bike is nutty...the throttle cable splits above the carburetor and one line goes into the tranny case.  What the hell is that for?

I'm trying to get her to fire over and all I get is little puffs of smoke...bleh.  Maybe I should just slap my XJ400 motor in her haha

Uh Oh if it splits off of and Goes into thee tranny there should be an oil pump I Think.With a Single Cylinder such as yours you shouldn't have to worry about it just Premix it to 32:1.

yeah I figured tha out...it has an oil injection system.  Just premix.

not going to matter if the motor won't run, though.  I think one or more of the rings are stuck.  I'm pulling the head off tomorrow to look.  While it puts out enough air you blow your finger well away, it doesn't hold pressure for long.  I guess we'll see.

The ONLY way to change wheels/tires:



I love two-strokes...wanna know what their guts look like just go out and pull their heads off!









I was going to pull the jug, too, but I didn't have the right extension handy...my tool just wasn't long enough for her .

The cylinder walls are baby-ass smooth, and the piston is reletively clean.  I don't think there'll be anything really wrong with the rings.  What else can it be?  We got compression, fire, and fuel...I mean how much more complicated can a solid-state 2-smoker be?