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  1. #1
    bainer1290's Avatar
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    The GP rebuild again...

    Well I have managed to tear down the engine and take a look at the crank. I didn't find and debris in the bottom of the crank case fromt he piston failure and the bearing all spin freely. I am pretty confident that the crank got away un-harmed. I got new domes from HCP Designs, F/A's with outerwears from HopatcongGPR and Zig has a side draft on its way to me. Thanks again guys!!!!

    I also pulled the gas tank to tke a look inside and to setup my dual pickup, kinda similar to the FAQ for the GPR's using the clunks. I also "modified" the Group K separator so it will have two remote pumps feeding it and three outputs at the bottom. I looks like some sort of bomb, I had the hoses on it to pressure test it for leaks. The remote pumps simply feed the separator and then I will also run the on-board pumps to feed each the carbs. This should eliminate any fuel issues.

    I have two cylinder head bolts that are pretty much stripped so I got heli-coils for them. I also got a set of the pressure testing plates from Jeff (kansasgpr) and his spare seat cover. I need to get some black to do the back seat because he only had the front cover. Things are starting to come together, too bad summer is over here in Canada, I won't be able to ride until April

    I'm currently looking for an intake grate (Pro-tec or R&D) and some black Hydroturf. PM me if you have either.

    What do you think?
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  2. #2
    Flying Scotsman's Avatar
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    Now you have a winter project.

  3. #3
    bainer1290's Avatar
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    Got the cases back together today, put in all new seals also.

    Still waiting for a few more parts to arrive then I can get on it
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  4. #4
    Moderator OsideBill's Avatar
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    Did you use the Motoseal laying on the bench to seal your cases? Have you read this thread? http://www.greenhulk.net/forums/showthread.php?t=14244 This is a great how to on assembly applies to any motor not just GPR's

  5. #5
    bainer1290's Avatar
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    You bet that is a great thread. I did use the Motoseal, I have used it lots in the past on my old YZ 125 seems to work really well.

  6. #6
    bainer1290's Avatar
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    Got the intake in today, looks nice. F/A's just barely fit

    Also made a bracket out of a piece of aluminum to hold the carbs together and to act as a mount for the throttle cable. It isn't pretty but it will function.

    Look at how the reed cages don't really match the holes on the intake manifold. The reed cages are more oval shaped and the intake is round. I could grind them down a bit to make them fit better but I can only take off so much material as there isn't that much meat left on the cages. Any other ideas?
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  7. #7
    I'd open that manifold to match the reed cage. Just do it real slow and take your time. Its easy to take it out and not so easy to add material back. I'd take a sharpie and mark the opening where the reed cage meets the manifold. Slowly start to round the edges of the manifold out to match the opening and the angles on the reed cage.

    If this is hard to understand I can take some pics of the ones I've done. Its really pretty easy, just time consuming to get everything to match how you want it.

  8. #8
    bainer1290's Avatar
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    That's what I was thinking, I'll pull out the dremel tomorrow night.

  9. #9
    cfgp927's Avatar
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    I'll second the notion of matching the two pieces. You're going to like that side draft manifold.....just make sure you keep the socks on your f/a's. Any water that finds it's way into the bottom of the hull is now more easily sucked into the motor, while you're out there tearing it up.
    Mike

  10. #10
    Moderator OsideBill's Avatar
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    How much material is there on the reed cage? I would be very cautious removing material on the cage, also make sure anything you remove from the manifold does not affect the seal on the carbs.

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