RD400 of Doom – First Rebuild

Well, that didn’t take long…

Kate, a friend, and I were headed downtown to a concert. Easily doing a buck-ten for several miles (on a closed course with professional drivers… duh), our friend, Chris, pulled up next to me and pointed to his gas tank. So we pull off. Kate’s having some problems shifting so she pulls to the side of the road and I follow while Chris runs up to the station. Won’t shift. Not up, not down. I fearfully unscrewed the dipstick to check the oil in the bottom end (as I’d done a few days prior), and only smoke came out. Don’t know where the oil went, but the bottom end was very unhappy.

As far as I could tell the top end was fine, the crank was fine. The clutch was fine. It’s clearly either some gears welded together or a bent shift fork.

And even though I was a little bummed, I was also kind-of excited, because I really wanted to tear into this motor anyway. So come along on this journey with me.

All prepped for surgery, let’s begin.

Motor out with the help of a friend.

So… Something clearly going on here. I’m thinking the right side is / was running lean? Did check the plugs over the weekend, and they read perfect. So this could be remnant of a prior issue.

Now I’m not in any way an expert, and still relatively new to two-strokes, but the transfer port looks really choppy. Almost like someone started to do a port job and realized they’d had too much to drink, but not so much that they didn’t have some sense left to make them stop. I dunno. Maybe that’s normal.

Intake port. Again, it’s hard to see in the picture, but it’s all so rough…

Exhaust port. Same thing.

Piston looking pretty pitted.

And then there’s this guy… It looks like it was about to hole any second. This is the clean (and I’m assuming too lean) cylinder. The thing looks awful. Also, I was told that this bike had fresh Wiseco pistons in it. Obviously not the case. BUT IT WILL SOON.

Piston windows. Just in case you were dying to know what those looked like.

And this is as far as I got last night. Thanks to my lack of a giant socket for the clutch basket. I believe it is a 29mm and I only go up to 27mm except for a few special ones I’ve purchased. I’ll pick it up on the way home from work today and finish the tear down / inspection.

I’ll keep this post updated with my progress. It might get crazy up in here, so just bare with me.

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Wednesday, March 20th, 2013 RD400 Cafe Racer 1 Comment

RD400 of Doom Updates

Just a few little things going on with the RD400 of Doom…

I made this little plate to mount a few dash-type things to. Came out pretty swell I thinks.

Here’s what it looks like mounted.

Meanwhile, My good friend Junior was hard at work on a little bracket for the rear master cylinder. The PO shaved the bracket off of this frame, so we had to make a new one. Of course he put his own style into it.

I then moved on to working on mounting the slave cylinder I picked up to convert her to a hydraulic clutch. Junior saw what I was up to and was like, “No, no.. you leave this with me… It will be amazing…” – and since he’s an amazing fabricator, it surely is amazing.

I even asked him to scratch his moniker into it. After-all, you have to sign your art.

Stay tuned for the completion of the hydro-clutch.

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Thursday, March 7th, 2013 RD400 Cafe Racer No Comments

Motor and Wheels

So another pretty common question going around the Beemerverse is, “What spine lube do I use?” The most common answer: Honda Moly 60. You can get this stuff at pretty much any Honda bike dealership. Funny story… I went in and grabbed some and the guy behind the counter was like… “What do you people do with this stuff? You BMW guys… ” Because apparently BMW owners come into this store all the time and buy this stuff. I explained what it was and why it’s delicious.

Anyway, I threw it on my clutch spline and final drive/wheel spline.

Applying Honda Moly 60 to Final Drive

Applying Honda Moly 60 to Wheel Spline

We got the motor back in the frame, (sans oil pan… that would have been difficult (read: impossible)). I threw the new oil pan gasket on there and bolted it all back down. So looking forward to not having a leaky bike.

Installing R65 Oil Pan

And this is how she sits.

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Thursday, December 30th, 2010 BMW Cafe Racer No Comments

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