Posts
157
Joined
10/12/2013
Location
Roselle, IL
US
Edited Date/Time
10/20/2013 7:57am
Help. My CR125 was running ok all summer until I the bike and I went down going around a turn. the bike revved for 5-7 seconds before I could shut it off. The bike was laying on it's side. When I stood the bike back up and tried to start it, it had no compression. I got it home and took the head off. The piston had a hole in it and the Cylinder wall was trashed and the cylinder head was trashed. I also noticed the power exhaust valves (RC valves) were "stuck" in the full open position, from carbon buildup. So the bike was running this way for likely many months or longer. I bought a new cylinder jug, head, piston kit (standard 54mm), power exhaust (RC Valves), and gasket kit. Put it all back together with the piston installed per instructions and so on. Started it up. Did a break in procedure (ran for 10 minutes at idle, then shut it down to cool off). did this 2 or 3 times. Took the bike out for a ride up and down my neighborhood streets. It ran ok, but I could tell something was wrong. It had low end power but mid and high rpm range it ran poorly. Then it happended. The bike died out at mid to high rpm in 3rd gear. Had to walk it home about 1/2 mile. Took it apart. The top of the piston was damaged and the head was damaged. Cylinder walls were ok, power exhaust (RC valves) were ok.
WHY IS THIS HAPPENING?
A couple of things you need to know:
1.when I put the motor back together and went to start it up (with all new parts) I noticed the compression was low. I did not take a reading, but by kickstarting it, I noticed it was much lower than it was since I owned it. This concerned me very much, but this was my first 2-stroke rebuild and I thought it might be normal for a new piston/cylinder install prior to break in.
2.blows lots of smoke - but it always did and ran fine before
3.i did not check, or replace the Reed Valve - ever!
4.the piston (Wiseco standard) was indeed installed correctly (had an arrow to indicate which way to install)
5.i used a torque wrench for all cylinder and head bolts/nuts
6.the radiator was full and the water pump appeared to be working because the hoses were getting warm when I was running it during the break in (sitting on the stand idling)
7.I did not check or even think about the "bottom end" Never looked at or touched or inspected any of that.
8.running 32:1 mixture - standard 87 octane gas (normally works fine)
9.carb has been rebuilt by me recently and is good, has standard jetting and settings. Float level is good.
10.running standard spark plug
11.the power exhaust valves (new) appear to be installed and working properly but I don't know for sure. I can move them by hand with the bike off by pushing/pulling the control rod from the governor assembly. There is also a possibility that I did not install the power valve assembly correctly. There are c-clips, washers, a couple of range limiters and a spring that all go together on the end of the rod. I'm 75% sure I did it right, but not 100%. I compared it to photos I took and assembly diagrams and it seems to be right, but I'm not sure.
12. the bike year is 2000.
SEE ATTACHED PHOTOS OF THE LATEST PISTON DISASTER.
thanks for reading this and thanks for your help. Lee
WHY IS THIS HAPPENING?
A couple of things you need to know:
1.when I put the motor back together and went to start it up (with all new parts) I noticed the compression was low. I did not take a reading, but by kickstarting it, I noticed it was much lower than it was since I owned it. This concerned me very much, but this was my first 2-stroke rebuild and I thought it might be normal for a new piston/cylinder install prior to break in.
2.blows lots of smoke - but it always did and ran fine before
3.i did not check, or replace the Reed Valve - ever!
4.the piston (Wiseco standard) was indeed installed correctly (had an arrow to indicate which way to install)
5.i used a torque wrench for all cylinder and head bolts/nuts
6.the radiator was full and the water pump appeared to be working because the hoses were getting warm when I was running it during the break in (sitting on the stand idling)
7.I did not check or even think about the "bottom end" Never looked at or touched or inspected any of that.
8.running 32:1 mixture - standard 87 octane gas (normally works fine)
9.carb has been rebuilt by me recently and is good, has standard jetting and settings. Float level is good.
10.running standard spark plug
11.the power exhaust valves (new) appear to be installed and working properly but I don't know for sure. I can move them by hand with the bike off by pushing/pulling the control rod from the governor assembly. There is also a possibility that I did not install the power valve assembly correctly. There are c-clips, washers, a couple of range limiters and a spring that all go together on the end of the rod. I'm 75% sure I did it right, but not 100%. I compared it to photos I took and assembly diagrams and it seems to be right, but I'm not sure.
12. the bike year is 2000.
SEE ATTACHED PHOTOS OF THE LATEST PISTON DISASTER.
thanks for reading this and thanks for your help. Lee
On a closer look, some of those marks look very close to the size of circlip wire diameter.
The Shop
thanks so much for your help. I agree the crankcase has to be cleaned up, there is likely metal pieces in there from the first piston that blew up, and I never cleaned out the crankcase. Having said that, I am not a bike mechanic. I am a "jack of all trades" and pretty handy and have built V8 car engines, but never pulled apart a dirt bike crankcase. Is this something I can do myself or am I getting in over my head here? I can buy a nice working used bike for about $900, or spend hundreds of dollars rebuilding mine and hope I don't screw it up.
Is this something I should tackle or just sell the bike as is and get another used one. I consider myself a good mechanic but I am not a trained experienced 2-stroke bike mechanic. I have just basic tools. I do have a complete service manual and that would help me. I looked at it and the job looks pretty big and complex.
?????
www.tdc2strokeperformance.com
Yes, it is a "free country" so you can also expect the "free advice" to end when the mouth gets out of shape as well!
I can only speak for myself in telling you, you were given very good info and help by me and others and have chosen to ignore it and become a complete foul mouth low life. I would bet that if the answers were costing you money then there would have only been " one and done". I have only been working on the bikes from about 1968, so what do I know?
Let's face it...You put together a "time bomb" and it let go and now all you want to do is cry about it and see if someone will make you feel better about it. Well.......Get over it and let the knowledge base help you instead of acting like a baby!
Have a nice day!
What are your thoughts on the "low compression" after the rebuild? Like I said, new wiseco piston and ring (end gap correct) new cylinder, new cylinder head, new gaskets, proper torque settings. When I did the kickstart process, it was very easy to do, compared to the compression prior to my top end rebuild. Why would that be? I would have thought the compression would have been higher.
Just curious, what made you go with the Wiseco ?
Pit Row
Regarding the Wiseco piston. I chose that because it seems what lots of people use where I ride and I've always known of them since I was a kid. I thought it was considered an upgrade compared to OEM pistons. Was I wrong? It seems like there are only 3 or 4 piston manufactures out there and Wiseco seems very popular. (namura, wiseco, pro-x, Honda) ?
Enough said !
Wiseco pistons are junk, but didn't cause this damage.
I would love to keep the bike and tear the crankcase apart and rebuild it, but I need to know that I have a "working bike - ready to ride" and not one that's always being worked on because I messed something up in the motor.
If you don't feel like you can do that or don't feel like you have the ability take the engine down that far to fix it correctly, then selling it may be the answer.
The correct fix is not brain surgery, but it does require attention to every detail.
I will be glad to help you in any way I can, but your service manual has most of the info in it for the job, including the tools needed for the job.
There are several reputable engine rebuilders out there. Not sure if Eric Gore is still doing them, but Jakes Dad mentioned another in an earlier post. I would bet even someone in your area could help you out.
Motorcycles break. No guarantees on a used sickle or a newly rebuilt engine.
That's a choice you have to make.
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