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New Top End On 92


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#1 TDrummer

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Posted 17 December 2018 - 01:53 am

My 92 is an oil user. In anticipation of top end overhaul, I have a set of OEM 2nd oversize pistons, rings, wrist pins, gaskets, etc. that I've been storing for over a year.

 

With winter here, I had my shop run a compression test:

Around 50 PSI in each cylinder. "Alarming" was their comment.

 

The head and cylinder is now off the bike.

The cylinder has been sent to machine shop for boring and restoration of the cylinder coating.

Upon inspection of the valves, the amount of carbon built up on the exhaust valves convinced me to replace all the valves and valve springs.

 

The pistons show clear evidence of quite a bit of blow by. The oil rings are quite worn. Between the condition of the pistons/rings and the condition of the valves, not to mention the low compression readings, it was due time to tear down the engine.

 

This is the last major area of the bike to be addressed. Carbs have been rebuilt/rejetted. Exhaust is now a 2 into 1 muffled by an OEM Kawasaki ZX14 muffler. The steering head bearings have been replaced and Race Tech fork springs installed. The swing arm bearings have been replaced and the factory shock has been replaced with a custom-built unit from a great suspension shop out of North Carolina. The seat has been recovered with a custom cover with a gel pad installed. Bars are Renthal aluminum Street Fighters. Head and tail lights are LED. 

 

Excited to experience the feeling of a new top end...



#2 dapleb

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Posted 17 December 2018 - 03:29 am

There is no cylinder coating!
"Whats up", "Piston Broke", "Yeah me too...hic"

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#3 fixitsan

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Posted 17 December 2018 - 09:14 am

There is no cylinder coating!

 

There isn't too.....but if you can get one it might be well worth it. Plenty to choose from nowadays too


9'er with a 17" front wheel and Samios remap  :)  happy days


#4 Pedro

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Posted 17 December 2018 - 09:50 am

what's the mileage on the bike? just curious because i've got a '92 as well



#5 Studley Ramrod

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Posted 17 December 2018 - 10:14 am

 

There isn't too.....but if you can get one it might be well worth it. Plenty to choose from nowadays too

 

From my limited experience in looking into this, coatings are generally only used on aluminium sleeves, well, at least the nickasil coatings are.  Mk1 has iron sleeves.


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#6 fixitsan

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Posted 17 December 2018 - 10:58 am

 

From my limited experience in looking into this, coatings are generally only used on aluminium sleeves, well, at least the nickasil coatings are.  Mk1 has iron sleeves.

 

Yes it's true. There's some ceramic wizardry on offer these days for various liners. Apticote is one which can be applied to steel/iron liners.

 

I'm wondering about the 900 and it's 'ceramic coating' on the bores (as advertised elsewhere...) , steel liners with a coating....or were they just nitrided before they were fitted ?


9'er with a 17" front wheel and Samios remap  :)  happy days


#7 dablik

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Posted 17 December 2018 - 11:23 am

What's the mileage at TD !


Bigred mk1 R1 Calipers- Braided lines- Givi wing rack-Crash bungs- Hi vis bullets-PR2's- and a hoot to ride.

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1991 MK1 in need of some TLC watch this space  :) Sorted and on the Road Mick :P :P it's the bike that Jack built ;)


#8 TDrummer

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Posted 17 December 2018 - 04:53 pm

There is no cylinder coating!

 

well there should be dammit


what's the mileage on the bike? just curious because i've got a '92 as well

 

around 65,000


 

There isn't too.....but if you can get one it might be well worth it. Plenty to choose from nowadays too

 

I think they do Nickasil? Maybe they add it if not there already. Iron, not sure. This machine shop came highly-recommended and has a history of lots of great work. 

 

Now I'm curious...


Edited by TDrummer, 17 December 2018 - 04:54 pm.


#9 Pedro

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Posted 17 December 2018 - 06:16 pm

Thanks. It would be interesting to hear the result after the work has been done.



#10 TDrummer

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Posted 17 December 2018 - 07:13 pm

Thanks. It would be interesting to hear the result after the work has been done.

 

I'm excited. Can't wait to share what I find out.



#11 TDrummer

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Posted 19 January 2019 - 07:53 pm

I know everyone's on edge of seats waiting for more news about this!

 

OK, had to send the head out to have new valve seats cut.

I chose not to install new valves and springs on the old, somewhat worn seats.

Observed by the technician: these five valve heads have really nice ports, no need for any work.

 

Bored cylinder (nikasil-free) and new pistons have been installed.

 

The bike will be ready to ride before I am.

Still healing/recovering from slamming myself into the tar while on my other bike (KLR650), last September. (I'm happy to share the morbid details if any interest.)



#12 fixitsan

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Posted 19 January 2019 - 08:47 pm

I slammed into the tar onmy ktm620 in September after hitting a parked deer. Broken right collar bone

What happened to you ?

9'er with a 17" front wheel and Samios remap  :)  happy days


#13 TDrummer

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Posted 20 January 2019 - 04:37 am

I slammed into the tar onmy ktm620 in September after hitting a parked deer. Broken right collar bone

What happened to you ?

I feel your pain!

 

Broke right shoulder in two places

Eight cracked ribs

Punctured lung

Traumatic brain injury with bleeding

Almost two months hospital

Two lane highway, one lane repaved, lane I was originally in, original pavement

The repaving crew was half-finished

 

About a 4 inch lip to go up going into the repaved lane - tallest one I ever remember seeing

My ego: "yeah you can make that - no problem"

The road: "idiot!"

 

It's recommended I wait one year to be clear of risk if I hit my skull again

 

Best I can do is visit the TDM at the shop doing to work 

Today the cylinder went back on

Head is shipped off to machine shop

 

Hope your healing and riding



#14 fixitsan

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Posted 20 January 2019 - 09:45 am

I feel your pain!

 

Broke right shoulder in two places

Eight cracked ribs

Punctured lung

Traumatic brain injury with bleeding

Almost two months hospital

Two lane highway, one lane repaved, lane I was originally in, original pavement

The repaving crew was half-finished

 

About a 4 inch lip to go up going into the repaved lane - tallest one I ever remember seeing

My ego: "yeah you can make that - no problem"

The road: "idiot!"

 

It's recommended I wait one year to be clear of risk if I hit my skull again

 

Best I can do is visit the TDM at the shop doing to work 

Today the cylinder went back on

Head is shipped off to machine shop

 

Hope your healing and riding

 

 

I was riding 10 minutes after, but then not for another 6 weeks !

 

I was riding a KTM620 Duke I had bought 10 days before and I hadn't been out in the dark with it previously so i didn't notice the headlight aim was very low, the beam was concentrated  at a point about 15 feet in front of the front wheel

 

 I had fitted some heated grips  and thought i would take her out for 10 minutes to make sure they work well. It was just dropping dark but it goes dark very quickly here. I was only doing about 35mph and with the darkness became aware that even on high beam the headlight was useless, and got as far as thinking 'I'll have a look at that tomorrow' , and as I went over the top of a gentle swell in the road 3 deer appeared in the headlight as it's aim was temporarily raised, they were nose to tail across the width of the road, probably startled by the noise of the bike because they weren't moving and were less than 10 feet away.

 

I knew I banged my head on the way down because when i tried to get up to my knees i kept falling down so after waiting a few minutes, knowing I was in a mobile phone blackspot and the next car along wouldn't be for a while, eventually got to the bike and tried to pick it up. I already knew my shoulder had gone and my ribs were hurt but struggled and hoped the bike would start, which it did first time. I had to lift my right hand onto the throttle with my left hand, and was only 3 miles from home.

 

When i got home I  said "A&E" to my wife in between taking tiny breaths of air, and it took me a couple of minutes to get into her car due to the pain of bending)....and it was then that I realised the front pockets had been ripped off my trousers as I slid forwards on the ground and therefore I had lost my wallet. Being a Yorkshireman i insisted we go back to the crash site on the way to hospital, and my wife spotted my broken wallet and line of cards and drivers licence spread down a 20 foot strp of the road.

 

Once I got to hospital and was checked in we sat down in reception and that's when i assume the adrenalin wore off, because I just turned to her as the pain level suddenly shot up and said "I think I'm going to....."   and then woke up in a cubicle some time later.

 

Only a broken collar bone and stripped the muscles out from between a few ribs, thankfully the head injury was minor, grateful for a fibreglass helmet and not a cheap polycarbonate one

 

Bike was less than £80 to repair,


9'er with a 17" front wheel and Samios remap  :)  happy days


#15 curlylegend

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Posted 20 January 2019 - 11:25 am

 

 

I was riding 10 minutes after, but then not for another 6 weeks !

 

I was riding a KTM620 Duke I had bought 10 days before and I hadn't been out in the dark with it previously so i didn't notice the headlight aim was very low, the beam was concentrated  at a point about 15 feet in front of the front wheel

 

 I had fitted some heated grips  and thought i would take her out for 10 minutes to make sure they work well. It was just dropping dark but it goes dark very quickly here. I was only doing about 35mph and with the darkness became aware that even on high beam the headlight was useless, and got as far as thinking 'I'll have a look at that tomorrow' , and as I went over the top of a gentle swell in the road 3 deer appeared in the headlight as it's aim was temporarily raised, they were nose to tail across the width of the road, probably startled by the noise of the bike because they weren't moving and were less than 10 feet away.

 

I knew I banged my head on the way down because when i tried to get up to my knees i kept falling down so after waiting a few minutes, knowing I was in a mobile phone blackspot and the next car along wouldn't be for a while, eventually got to the bike and tried to pick it up. I already knew my shoulder had gone and my ribs were hurt but struggled and hoped the bike would start, which it did first time. I had to lift my right hand onto the throttle with my left hand, and was only 3 miles from home.

 

When i got home I  said "A&E" to my wife in between taking tiny breaths of air, and it took me a couple of minutes to get into her car due to the pain of bending)....and it was then that I realised the front pockets had been ripped off my trousers as I slid forwards on the ground and therefore I had lost my wallet. Being a Yorkshireman i insisted we go back to the crash site on the way to hospital, and my wife spotted my broken wallet and line of cards and drivers licence spread down a 20 foot strp of the road.

 

Once I got to hospital and was checked in we sat down in reception and that's when i assume the adrenalin wore off, because I just turned to her as the pain level suddenly shot up and said "I think I'm going to....."   and then woke up in a cubicle some time later.

 

Only a broken collar bone and stripped the muscles out from between a few ribs, thankfully the head injury was minor, grateful for a fibreglass helmet and not a cheap polycarbonate one

 

Bike was less than £80 to repair,

 

Shit !  That could have been very serious.  Someone could have come along and lifted the contents of you wallet.  Glad you managed to recover them.... a man after my own heart !



#16 fixitsan

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Posted 20 January 2019 - 12:02 pm

 

Shit !  That could have been very serious.  Someone could have come along and lifted the contents of you wallet.  Glad you managed to recover them.... a man after my own heart !

 

Indeed i couldn't joke about the whole thing now if my wallet had of gone too... It's not just the financial loss, all i could see in front of me was days of telephone calls and application forms to reinstate the lost cards and driver's licence... no thanks !


9'er with a 17" front wheel and Samios remap  :)  happy days


#17 TDrummer

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Posted 21 January 2019 - 05:33 pm

 

 

Bike was less than £80 to repair,

 

I'm glad I'm not the only one who sacrifices body to minimize damage to bike.

I had a scuffed up saddlebag but that appears to be the only thing wrong.

 

Coincidentally, as I had been spending the bulk of my riding on the TDM (who wouldn't???), I had only taken the KLR out to give it a little exercise.

If I had been on the TDM, I think I could have negotiated the road without major mishap.

The KLR, not so much.

 

I have zero memory of that ride, the crash, or the next week and a half.

All I know is I found myself in the rehab hospital being told I couldn't go home.

 

"But I am going home!!!!"

"No, jackass, you can't walk!! You have to relearn before you even think about getting released!" 

 

Doctor advises one full year before I ride again. (brain re-injury risk).

 

At least my classic 92 850 will be almost 100% as good as new or better when I'm ready.

I can't wait.

I love this bike.


West Lothiam? Scotland?

My cousin live in Bristol UK.

My father born and raised in Liverpool.



#18 fixitsan

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Posted 21 January 2019 - 11:45 pm

Liverpool is good but the best bit has to be the canal which reaches to Leeds where I'm originally from :)

9'er with a 17" front wheel and Samios remap  :)  happy days


#19 dablik

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Posted 22 January 2019 - 08:44 am

Liverpool is good but the best bit has to be the canal which reaches to Leeds where I'm originally from :)

 

:rolleyes: :rolleyes:  :rolleyes: 


Bigred mk1 R1 Calipers- Braided lines- Givi wing rack-Crash bungs- Hi vis bullets-PR2's- and a hoot to ride.

Quad 900 Silver Laser duo tech pipes-Scott oiler-Engine crash bars- Radiator mounted see me ring LED's-Datatool system 3 alarm -Centre stand- Extender fender-Renthal bars-Handle bar risers-Mirror extenders-BMW GS Handgaurds-Acumen uprated horn & Nautilus-Stainless steel Radiator guard-Givi wing rack-OEM screen-Yammy touring screen-MRA Vario-MRA Double bubble cut down for fast as fk riding-Tiger screen-Tank protector-Stomp grip panels-Optimate lead

 

1991 MK1 in need of some TLC watch this space  :) Sorted and on the Road Mick :P :P it's the bike that Jack built ;)


#20 fixitsan

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Posted 22 January 2019 - 09:06 am

 

:rolleyes: :rolleyes:  :rolleyes:

 

 

Well, it wouldn't be right to talk about it's incredible architecture, rich history,  it's importance as a port, or the football team


9'er with a 17" front wheel and Samios remap  :)  happy days



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