My engine R&R progress

[kinger]

Well I started yesterday torqing the engine mounts and finsihed today installing the carbs. Great progress first off I got it aligned, this is a PITA but the handle bar alighnment tool from mountain perf made it easier, you basically lock the steering column from turning and you can then focus on the front. Main thing here is keep the distance on the tie rods the same on each end. This took me a long time because it was just me, I had to 'tape' the tape measure to the center of the rear and then run to the other side and measure, then the front, then back and so on till I got it set to 0 toe for my simmons. Running single carbides 1/2" toe out is ok.

I love how the GYTR's look, hopefully they perform as good!

Next picture is that of my oil screen on the bottom of the oil tank, my sled has 3300 miles on it and the engine has been out before and therefore this screen might have been cleaned once already. Switching to Mobile 1 0W30 and will monitor this screen. For those that don't know it comes out with 2 - 5mm allen screws on the bottom of the tank.

Next picture I spent some time polishing up the valve cover, as you can see the nitrous system hides so only I will no it looks nice

Then my pretty battery cage that again no on else will see but me....

Next up the nitrous system before the carbs go on, everything tucks nicely into place. The jets are pointed into the throat of the cylinder and deliver nitrous and race fuel from a seperate tank. This is a little more tough of a system to install but I think its worth it, it seems to hit harder then most other system although I need to get on radar to determine that for sure or not. I have seen 156 mph on the dream meter with a 25T top gear and Cb perf custom clutch kit.

Last pict is the carbs on and ready for filters.

I didn't run into any snags so far that were not easy to fix. I also cleaned the carbs before mounting and 3 out of the 4 were plugged. Imagine that.... :ORC

I have a LOT of details to take care of before I get close to firing but up next is the handle bars which will take some time because there is a order to it and if you do it wrong I'm sure I will have to re-do things 3-4 times before hitting the right sequence. Once I get the bars in place and tank cover, I'll add the rear heat exchanger and filler up with fluids, bleed the oil system (or prime it rather then bleed it) and try to start it this week. I pray to everything holy that there are NO LEAKS!

 

[tofast]

me to

i was hearing some annoying sound and all of my exhaust clamps were lose so i grind my spacers and it fixed it

 

[kinger]

Thats one way, the correct is to buy new gaskets, the spacer is there to prevent over tightening. 7 ft-lbs is all the TQ to use. If you ever replace the gaskets you will need to replace the clamps now to because you will overtighten and crush the new gaskets.

 

[JDMCRX]

The fun eh Looking good man

 

[kinger]

Almost ready, got all the wiring done and only waiting on longer Throttle and choke cables and my rivet gun I had to buy to use the 6mm rivets for my rear heat exchanger I added, then I'm firing this beyatch up!!!

 

[kinger]

Well I got everything installed and fired her up! The LB trick of blowing int he vent hose and holding the pressure there with your thumb worked great, she whirled over about 8-10 times and sputtered as each carb got fuel, then VROOM! With the awesome fercious growl! Runs and idles real nice I just need to get the oil cirulation system bleed properly I get some circulation but its not consistant yet so I haven't gotten it really warm. Hopefully this week I'll get that flowing and then bleed the coolant system and call this part of my project DONE! My new camera charger is in so I will be able to post a picture and end this thread and start a new one in the garage with all the other mods.

Lessons I learned so far working on these 4 strokes as this was my first engine removal and replacement:

Marking everything as it comes off cost me about 20 minutes but probably saved me 2 hrs on install and attributed to the quick fire up with no leaks or issues.

Always double check things you did the day before when starting the next day, you get burnt out and miss some things especally when you have to go a week or so before getting a opportunity to work on it.

Time: Took 10 hrs 30 mins to pull the engine out and set on my work bench I coudl easily do that in about 6 hours now

Took about 8 hours to install it and hook everything back up and ready to fire. That is about as fast as I would want to go. Keep in mind that I have some extra things that a stock engine would go much faster without those (ie nitrous blocks, Nitrous mounting, wiring, etc)

The chassis is really well engineered from a service perspective, I was amazed at how they packed everything in there so efficiently going in order of system( oil system, coolant, wiring system, etc) it all just falls into place.

There is nothing on removing and replacing a engine that is 'hard' its all nuts and bolts, no special tools required, if you keep good notes on the way out everything falls into place on the way back in.

Overall I'm glad I did this and I think I may look for anotehr project RX since they are so cheap adn everyone wants a apex, I still love the RXs!

Picts to come within a day or so.

Thanks TY!!!

 

[kinger]

Back to the top!

Well if you followed my previous posts on the oil priming issue you knew I was waiting on my new rebuilt engine after it was repaired for free by teh dealer. Great guys but now I have a lot of work to do!

Today I started with a frame pretty much. NO chain case, no track, no driveshaft, no rear suspension, no engine, etc

I worked about 8 hours and made some good progress:

Chain case is all together and filled with fluid
Track is in
ZX2 is in
Driveshaft with doo extros is in
Engine is in and on its mounts
the steering gate is in and TQ'ed
Steering system is in and TQ'ed
Nitrous system is back in


Overall I feel good about the progress. The hard work is done and I just need to:

Install oil system (20 minutes)
Install coolant and water temp gauge (1 hour)
Install fuel tank (20 mins)
Install carbs /fuel pumps(45 mins)
Install air filters and EVAC (10 mins)
Install the battery cage (5 mins)
Install battery (20 minutes)
Check all wiring connections (40 minutes)
Finish up new NX fuel pump install (10 mins)
Install handlebars and gas tank cover and isovibe (1 hr)
Bleed brakes (30 mins)

That should be close, test fire, verify oil pressure, then put the panels together and seat, etc. Should make for a nice half day coming up!

 

[grader]

glad to hear things are working out after all the crap you went through. check your clutch alignment, center to center, and offset before you tighten down the motor.