Now, how does this thing go back together?

Well, seeing as most of the parts are here and the bike is almost completely back together I thought I'd write up how it went. And how to do it, for anyone yet to do one!



One little tip I have for those of you you have problems using cipclips. Take the old piston and circlip, and practise putting the clip in, and taking it out. So that if you do damage the piston in the process of learning it won't matter. After about 10 minutes of practising, I found a technique that worked where I could do it in 10 seconds flat!

Luckily, the piston I bought came pre-drilled! Phewww.. because I did not want to have to drill it myself!


First thing to do if install the new ring onto the piston. Then, insert the wrist pin bearing into the crankrod - lubing both the wristpin bearing and crankrod with a little premix. Then insert the piston, with newly installed ring onto crankrod, making sure that the exhaust valve hole are facing the front of the engine. Now, I found it a good idea, to wrap a clean piece of cloth around the bottom of the piston, so that I dropped anything, it would not fall into the bottom of the engine. On one side of the piston insert one of the circlips, being careful not to scratch the piston. Then, insert the wrist pin itself - again lubing with a little premix. Once that is done, insert the final cipclip.
Next, time to install the base gasket. First, I removed all remains of the previous gasket, to get a nice clean seal!
Picture of installed gasket and piston.




Next, the cylinder had to be installed. My manual suggested lubing both the piston and cylinder with a little bit of premix, but it is up to you whether you do that or not..?
When, inserting the piston into the bottom of the cylinder you have to squeeze the ring together. Once started, gentley push the cylinder on. When in place, tighten  the cylinder base nuts to the specified torque settings, as in your manual. For me it was between 25-30nm. When, tightening them, do them in a criss-cross pattern, 1/4 turn at a time - so is so that it does not warp.
Now, we have to install the new cylinder head o-rings/gaskets, for me it was two o-rings. I had to gently stretch the o-rinds so that they fitted correctly.
Picture of cylinder, and installed o-rings.




After that, time to install the cylinder head. But of all, Skip advised me to find a piece glass and some 400grit sandpaper. Then send the cylinder head, so that it was flat.
Then, carefully install onto the cylinder, being careful not to move to the o-rings from the little 'grooves'. As with the cylinder base nuts, the cylinder heads have a specifies torque setting as well. For me it again, was between 25-30nm. But refer back to your own manual for the exact specs. Again, tighten in a criss-cross pattern, 1/4 turn at a time!



Then, I had to install the two exhaust valve covers, with their new gaskets. Simple job, aint much too it.




That is pretty much the top-end complete. Just have to install the exhaust again. While, I had the exhaust off I took the time and replaced the exhaust packing, oh and imstalled the new exhaust o-ring.



Ohh... And connect all the radiator pipes up. And fill with coolant.

I also JB Welded my radiator back together, due to it being held together by cable ties!!


Right, thats it. Now, here's a few pictures of other bits going back on...







The only thing I am waiting on now, is a waterpump gasket.... And some new sparkies!

Oh yeah, almost forgot. Got a compression tester today. Hooked her up, and the height reading I managed was 120PSI?? Now, I am hoping you are going to say that is because it hasn't been run in yet...??



So... Now, it is yours turn to tell me what I have done wrong, because I am bound to have missed something out!!!!  
Joe.

Seeing as blue links are working again -
 
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The King Of Crumpets - Crumpet Boy!

- 1991 RM125

Only thing i do diffrently is, i dont lube the top ends. If you every read super hunky he swears by not pre lubing the piston or walls, as it can glaze and prevente proper ring seating, and yeah your low compression is do to the rings not being seated yet.  
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The Idle of a 500 2 stroke is Akin to the Devils Heartbeat


I'm not afraid of the dark, I own the NITEMARE that lurks within.

OH MY GOD.....Where to start! That whole engine needs to be re done!!!! WOW.  
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DIABETES SUX!

Yeah.. I just followed my manual so. Oh well.

Woods... You being serious?  
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The King Of Crumpets - Crumpet Boy!

- 1991 RM125

Naw great write up 92, and its up to you. Some guys swear by it. Im sure it'll run like a champ, and you did a really good job with the pics,a dn the build  
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The Idle of a 500 2 stroke is Akin to the Devils Heartbeat


I'm not afraid of the dark, I own the NITEMARE that lurks within.

Thanks DC, and at least someone is possitive towards all my work. You gotta remember this is my first top-end and I have had no help what so ever.. Only a manual, and common sense! And then there is Woods going OMG, new engine!!!!.....  
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The King Of Crumpets - Crumpet Boy!

- 1991 RM125

Oh yeah, and Woods you have to send me a bottle of Bel-ray H1R. I pictures of my ratio rite cup...

 
------------------------------------------------------------
The King Of Crumpets - Crumpet Boy!

- 1991 RM125

You want a list?  
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DIABETES SUX!

Yes...  
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The King Of Crumpets - Crumpet Boy!

- 1991 RM125

hahaha here's what you did wrong..

well first of all you err. umm. well. see what you did is.. well you didn't do.. ahh scwew it, you did a great job lol. explained everything, and took good pictures. hell you didn't even spell like anything wrong  
~Pat
life's a garden dig it!

Ha! Thanks Pat, I'm just intriuged by what is going to be on Wood's list!  
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The King Of Crumpets - Crumpet Boy!

- 1991 RM125

Great job 92! Was there any powervalve cables to reconnect?  
+++++++++++++++++++++

Even a broken clock is right twice a day.

Very nice write up 92!!

But a couple of questions.  do they recommend 20nm on the head bolts because its not a gasket?

is it set to return?? I think there is a procedure. don;t forget to check the compression after u run it. I'd like to see ur new reading.  

So I did good yeah, ML?

No idea, about the different torque specs for o-rings and gaskets.

Huh. Is what set to return?
Yeah, I will do a compression check, once it is finished and warmed up.  
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The King Of Crumpets - Crumpet Boy!

- 1991 RM125

chudster:
Great job 92! Was there any powervalve cables to reconnect?

Powervalve cables????    Nope... Should there be! lol  
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The King Of Crumpets - Crumpet Boy!

- 1991 RM125