RZ500 repair.

Jamathi · 02-06-2008, 10:36 AM

well my bike popped and farted on one cilinder, and we went in for a look after trying to kickstart it,it locked solid.
This is what we found after going in deeper.

Jamathi · 02-06-2008, 10:37 AM

Jamathi · 02-06-2008, 10:38 AM

This what we found!

Jamathi · 02-06-2008, 10:41 AM

New piston, oversize, if we can rescue the barrel somehow.
Bleeding shops are closed so now I can not order/buy/play any further till friday next week

XSorXpire · 02-06-2008, 10:55 AM

Ouch.

CT90 · 02-06-2008, 10:56 AM

Well done.

Jamathi · 02-06-2008, 11:13 AM

Checked the other barrel and me thinks a complete top end rebuild is happening, all four will be done.

druu · 02-06-2008, 02:39 PM

How did that happen? Did the piston somehow catch on the exhaust port?

smokeymatt · 02-06-2008, 03:05 PM

well at least is is easy fixed, none of those complicated valves, cams and camchains to worry about. What caused this?

Stratos · 02-06-2008, 03:18 PM

Owch dude!

Looks like somethings caught the piston and forced the fractured lip into the exhaust port.

Jamathi · 02-06-2008, 03:27 PM

Broken rings.
Do not forget tat this is a 1984 made machine!
Max revs who knows, but now all are getting new ones.
Top end over haul.
Will try and keep a log on it and take pictures along the way!
Due to FIFO and RG500 build, it will not be "overnight".
The gaskets and seals plus rings is going to be a decent amount sadly, never mind

Sprint · 02-06-2008, 05:09 PM

Damn. Ring breaks, takes some piston ring land with it, bore gets damaged by the piston's new-found lateral play - more land wears due to newly-fucked bore surface, another ring fails...

Was this the problem when we went out Bindoon way a few weeks ago? you reported a misfire at Bullsbrook where we stopped to re-group IIRC.

S.

Jamathi · 03-06-2008, 03:31 AM

Yep, I think so.
The lock happened while trying to start it after changing the CDU and luckily not at full cry.
first half kick and it locked, no running revs at all.
saved the crank and hopefully the barrel as well.
the scores at the buissnes end are hopefully not to deep and the top port area is already fixed.
next swing I'll hone it to see where we are with it.
I know where there are some barrels, but they are place specific on this model.

TORQ · 03-06-2008, 05:15 AM

Photographer needz less flash! Oh, and carn Bert, bit of Chemiweld and a polish, be good as new

Good luck.

Nero Diablo · 03-06-2008, 11:47 AM

Slightly off topic but who does two stroke rebores in Perth on multi cylinders?

Jamathi · 07-07-2008, 09:07 PM

Finally found time to pull of the other cilinder.
Now i know why it popped and farted!
Piston ring glands at the exhaust port are completely gone as are half the rings, the left overs just fell out!
damage to barrel is not to bad at first inspection.
I have been lucky in damage control and I am interested to see what the other 2 cilinders are going to reveal!

RAVENGSXR · 07-07-2008, 09:16 PM

Quote:

Originally Posted by Nero Diablo

Slightly off topic but who does two stroke rebores in Perth on multi cylinders?

Sorry to threadjack Bert !
I had my old RD barrels bored by a place called the bike doctor but this was many moons ago .

Good luck with this one mate

Hey Bert when's the KR thread coming ?

Jamathi · 07-07-2008, 09:27 PM

first the RG500 , parts are coming from Japan, so it can be put together and Spuddy is well into painting the panels/tank
after that the TD3,
Making a race replica out of the RD350,
Then the CBX-6 naked transformation and then.... the KR250, maybe make it a priority after the RG finnish.
The KR does not need a big amount of work like the others.
Now that I have the manual, I feel bound to prioritise it.
Thank you again!

RAVENGSXR · 07-07-2008, 09:33 PM

Happy to help mate

rgvlee · 08-07-2008, 08:30 AM

Are the bores plated? or just steel inserts?