300 rebuild…

thanks mate, but its new or nothing for the 3hungy

if you want a real knot in the stomach Axel, look at the videos on the ‘epic glenmaggie’ thread. i rode it like that for nearly 100km before i noticed…

it nearly made me sick :blush: :X

anyway, i got all the goodies from suttos yesterday and my new bench turned up….although it was damaged :angry: looks like it had a fight with a forklift :laugh: :laugh:
after a few phonecalls and some stern words, the manufacturer has decided to sort out the issue and send me a new top and some other bits…
it worked out pretty well. i wanted a 32mm mdf top but they wouldnt send it due to weight, only a 16mm.
now they are sending me another 16mm one, so i get my 32mm top :laugh: :laugh:

dickheads :laugh: :laugh: :laugh: :laugh: typical sydneysider :laugh: :laugh: :laugh:

im gonna go light the fire and check the ring gap, squish band, dimension ‘X’ and stuff this arvo.

i was gonna rebuild it saturday but im “told” im going to South Aus for a nookie weekend :blink: :laugh: sweet i say :laugh: :laugh:

via the great ocean road of course.

we just bought sammy a 2006 Corolla Levin the other week. its fully optioned and its a little rocket ship :laugh: it hangs on like shit to a blanket :laugh:

it ought to be a fun weekends drive

the rebuild will have to wait. :laugh: :laugh: :laugh:

ive pretty much talked myself into a scotts top triple clamp and underbar stabilizer kit. should be able to land it from seppoville for under $800AU.
otherwise a BRP clamp and mount, with a scotts damper, its a little cheaper

not sure i want BRP written on my bike though :laugh: :laugh:

axel wrote:

yep :laugh: :laugh: :laugh: ktm pricing :laugh: :laugh: :laugh:

if you look at the ‘prorider’ website, their kits are $239 but no group 2 in stock.
‘procycles’ (who are near suttos) do them for $263, and have group II pistons.

i found this out from “the 300 club” on DBW.

when i called Mal at Suttos, he started rattling on about $300+ pistons…

i stopped him with a chuckle and told him what i had found and he instantly matched it, well after he spoke to the boss anyway 😆
i quoted the $263 one because i could get it. i probably could have said $239 and got the same result but i didnt cause i couldnt get it.
maybe im too honest… oh well, im happy with the deal and i’d rather deal with Mal.
He was only doing his job after all and once he knew who i was and that i was from OBT, the salesmanship stopped and it was all smooth sailing

a couple of weeks before i was thinking i would have to source it offshore as the prices are bullshit here…..

i doubt i could walk into any bikeshop in melbourne and get that deal straight up so good on Suttos :woohoo:

i dont mind paying the freight because to be honest, i would have to travel at least 30 minutes each way down here to get to any bike shop i like anyway!! so whats $10-$15 bucks

suttos do a lot for us and i like to give them a go when its worth it.

i will be ringing Mal about my triple clamp and damper kit too. it never hurts to ask.

well the actual difference between the group 1 and 2 pistons is 0.025mm, or 0.010″ (ten thousandths of an inch)

or a poofteenth as my dad would say :laugh: :laugh:

group 1 = 71.025mm
compared to
group 2 = 71.050mm

i dont have the piston/bore tolerances yet, but i’ll find them, or ring MAl :laugh: :laugh: the 300 has a ‘square bore’ of 72 x 72mm going by the book. i dunno if i’d trust that number though..

Hmmm, square bore :unsure: …

i dunno what or how that relates to a 2 stroke? maybe nothing as we need ports and skirts and shit for induction.
i just remember my dear dad rattling on about it back when i was just a little tacker getting under his feet in the shed. he used to build sick arse engines for speedway beasts and the odd streetcar back in the ’70s :laugh: :laugh: it got him his whiskey money and he drank a lot of whiskey :laugh: :laugh:

i notice all the 450 and up thumpers have generally oversquare bores. (wider bore and shorter stroke) is that to fit bigger valves in or to help them rev higher….probably both i spose. piston speed might have a bit too do with it since the new bikes seem to have very little piston skirt….

i might have to have a look at my old TT350 specks in comparo to an XR400 and then comparo them both to some newerfangled WR400s and CRFs even, just for fun. :laugh:

pity ive gotta finally go back to work tomorrow, its got me thinking :laugh: :laugh: why didnt i think of that 3 months ago :laugh: :laugh:

need another thread for that anyway. :laugh:

i will start checking tolerences on the 300 tomorrow arvo. ive gotta drop into Billt’s and borrow all his tools first thanks buddy

im gonna have to searth TT for numbers for the ring gap and piston clearances. they dont come in the manual. (unless one of you good blokes know them :dry:

dont worry Axel, i will be checking everything thoroughly. the piston itself is made to wear far more than the bore.
it will wear some too, hence the group 2 slug.
i havent slipped the new slug in the bore yet but the old piston would rattle around in the bore at TDC with the head off if you pushed your fingers on it and moved it around. i’ll measure the slop on everything old and new tommorrow including dimension X and Z and all that jazz.

your right mate, there is a science to it, well prolly more a tolerance than a science but the same thought applies

if the new group 2 slug is too big, i just wont use it yet.
if the old one is well in spec, i might use it again as its in perfect condition. i will just put rings in it.
or if i need to i’ll just get a new group 1 slug kit, and keep the other for future loving…
whatever it needs

my ‘old skool’ old man used to say, “rebuilding any engine is really simple if you use good, accurate, measurement and that includes torquing things back up…and bend the specifications to your advantage”.

its easy to look at a rebuild and say “bugger that its too hard, i’ll give it to the shop to do” and fork out some big coin so someone else for the opportunity to work on YOUR bike!!

if its taken in small steps, and with a bit of encouragement, anyone can do it and it is very, very, rewarding, especially if/when it starts in 3-4 kicks and runs smooth and hopefully will for the next 150 hours :laugh: :laugh:

then theres the bragging rights that come with it too. :laugh: :laugh:

“hey, Menace you champion, how much did they charge ya for the rebuild mate?”

“about 300 bucks including beverages and i did it myself so now im highly expertized in it… i’ll do yours for a grand or so if ya want mate” :laugh: :laugh: :laugh: :laugh: :laugh:

or something like that :laugh: :laugh:

anyway, i’ll post it up as i learn it and do it, hopefully some one will be able to use it as reference in the future… and/or
tell me if ive mucked something up in the present… :laugh:

hey, im always open for CONSTRUCTIVE critisizm…. (shut up boony!)

and any tips welcome

and twobanger, my 300 has done 4320km in 108.2 hours.

next time you go for a ride, try to mentally average how many k’s you do every hour.
mine works out to 40km/h average over its life. i do a lot of open riding so its pretty high for a bushbike. if you do tight single track heaps it may be as little as 20km/h.

so if my bike had that many k’s on with mainly tight single, it would probably have 200 hours on it…

does that make sense dude :blink: :dry: :laugh:

axel wrote:

the powervalve was the dirtiest part of the whole lot. cooked on carbon and oil residue. if i had a wire brush for the grinder it would have taken about 5 minutes. it was more the contact surfaces on the PV flap shaft that i wanted clean, the rest is a bonus.

those blokes running 200hrs probably have 6 different ring gaps. that long on rings is looking for trouble. :angry:

yes i did put the group 2 piston in. it was pretty perfect to spec too.

Mal at sutto’s is the man Axel, he will look after you

Boltons probably sell single rings because the SX model only runs a single ring piston

i fixed my triple clamp too. mr big rubber hammer did a good job :laugh: :laugh:

still gonna replace the top one though when my damper arrives.