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Old 10-17-2012, 04:24 PM   #31
Gnarly Adventurer
Joined: Jun 2007
Location: Hayward,S.F. bay area
Oddometer: 192
I'm feeling a little envious of your rebuild. I want something similar so I'll be watching
this thread , day dreaming as always........
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Old 10-17-2012, 09:01 PM   #32
focallength OP
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Oddometer: 4,458
Originally Posted by 955616846 View Post
I don't think that the case inserts will be necessary and you still don't know the state of the crank or transmission...
Crank is being replaced, whole new hotrods bottom end, the onlything that may remain are the gears, (if their good, which they look ok from what I can see, ill know by friday )and countershaft, everything else is new (bearings/seals). The timeserts are just insurace, dont want to break a headbolt, it is possible, so better safe than sorry. Especialy since I wont know until it happens then id have to tear the engine apart again, $80 to be safe is money well spent. Plus those threads will never break with titanium inserts. Ive had a bad experience with a head seperating on a bigbore and ive heard enough war stories...not dealing with that crap again. Ill most likely even order some better head bolts, if im building this thing I might as well make it unkillable.

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Old 11-26-2012, 06:51 PM   #33
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Oddometer: 4,458
Sorry for the delay, got the cases back yesterday, bottom end is together and in the frame.

I had the timeserts put in, they were drilled a little deeper so I can put in longer head bolts. Maybe overkill but better safe than sorry.
Replaced all of the seals, bearings, the bottom end is brand new aside from the gears, they were in good shape. New hot rods crank.

Next is a 434 bb kit, just send the sleeve and for $419 I get a bored out sleeve, piston and rings.

The big hurt is the head, itll all be brand new, a blank head is 575

I need to replace the clutch and basket another $400

And ill get new bigger radiators to support the bigbore and increased compression as well as the hot cams.

Pics soon...
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Old 12-03-2012, 03:52 PM   #34
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Im going to try out mylers for the radiators. They sell oversized radiators for 135 so i ordered one to make sure it fits ok, ordered the millenium 434 bb kit.

They said it should fit ok with a clarke 3.9 tank. They look great and the added cooling should help with the 434 kit , increased compression and hot cams. I should have the radiator thursday and the bb kit some time next week.

Ill get lots of pics as the parts roll in.
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Old 12-29-2012, 01:43 PM   #35
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Ok, got the cylinder and piston installed
Millenium, with je piston 434 kit.

Painted the cylinder red, for a little pizazz, lets people know theres a little something special inside.
Gapped the top ring 0.02 mm smaller for a bit more compression.

I bought a new radiator to test it out, very well made, sides twice as thick as stock. Myers super cool radiator
Ill buy a new left one from them too. They say they can rebuild one of their radiators for iirc $45, even if its pancaked flat. The sides are easily twice as thick as stock, if not more.. I dont see them crushing, unless ran over by a dumptruck.

Im buying parts for the head, all kibbewhite, just trying to score a new head

So heres the score, hot rods bottom end, millenium bb kit with 434 je piston, myers super cool radiator. Kibblewhite springs/valves, fcr carb.
Titanium timeserts, with a little extra length for some uber head bolts.
All new gaskets and bearings, plus oil jet.

focallength screwed with this post 12-29-2012 at 01:52 PM
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Old 01-02-2013, 08:19 AM   #36
Beastly Adventurer
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Joined: May 2009
Location: Westminster CO
Oddometer: 1,295

If my DRZ motor ever dies ill be heading a similar route!
CRF250L | KTM200SX
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Old 01-03-2013, 06:50 PM   #37
Gnarly Adventurer
Joined: Nov 2009
Location: Central Missouri
Oddometer: 125
Check out Evans coolant to replace the antifreeze,cools alot better and wont boil over ! Use it in a 2stroke I have that was running hot in the slow stuff after that no problem !
08 DR 650
08 V-Strom 650 -Sold
08 KTM 300XCW - Sold
I must have sumthin about 08's
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Old 01-03-2013, 09:44 PM   #38
Bobby Ginger
Cat Herder
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Joined: Nov 2012
Location: N.E. FL
Oddometer: 926

Just found this, picking up a DRZ tomorow. If I ever have issues this will be handy.
2009 GSA 2008 Husky TE450 2013 Husky Terra
IBA 50407
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Old 01-24-2013, 09:39 AM   #39
focallength OP
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so a little update, got a new head and all the parts for it, except the hot cams which are on back order for a month. i just need the clutch primary gear and plates. a left radiator and right radiator sensor. i got a e model air boot and throttle cables for the fcr. aside from the cams and clutch primary gear i just need to order a header, ill prob. get a fmf powerbomb. so the parts are trickling in slowly and ive been organizing them and double checking. ive replaced almost every single part on the bike with new,oem or aftermarket. school has the bike on the back burner but ill get pics up as soon as everything is in.
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Old 01-24-2013, 09:53 AM   #40
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Joined: Jan 2005
Location: On a set of 50,000 mile tires.
Oddometer: 13,873
I would highly recommend that you waste a few gaskets and check your valve squish, you know, modeling clay and check for proper valve to piston clearance.

Stiffer valve springs I hope?
Be sure the safest rule is that we should not dare to live in any scene in which we dare not die. ~Lewis Carroll~
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Old 02-01-2013, 08:03 AM   #41
focallength OP
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Got my new header in yesterday


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Old 03-21-2014, 09:24 AM   #42
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Joined: Jan 2004
Location: Oaktown
Oddometer: 785
It's funny that what started as a "$800-900" rebuild ends up a 2.5-3x monster build :) It's a disease I tell ya....but should be worth it.
Pain is just weakness leaving your body
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