PPMPR: Project Poor Man’s Pro Race

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On Turkey day I had a failed radiator cap which culminated in over heating the bike. So I'm going to take this opportunity to install an actual ProRace kit on the bike. I had this this kit installed on the previous iteration of the Wicked GPR. I was having a oil leak with that engine, so I decided to pull it out.

To start this conversion I had to pull the top end from this engine.

With the top end off I noticed transmission oil in the crank case.

The wash was interesting. There's a good amount of carbon, which is desired, and some nice wash at the A and B ports, but almost none at the C port. Which is strange, and there's wash at the exhaust port.

To pull the piston I employed the net Treats piston pin puller. So nice to have this tool.

I noticed the wrist pin has some slight scoring.

The next step will be cleaning everything up, and prepping it for installation.

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Finally made it out to the Storage to work on the bike. The other day Shawn and I went to Harbor Freight where I picked up this nice work mat. Probably should have gotten one for both sides, but I already have the other square multi-piece units. This will make working on the bike much nicer.

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With the new mat in play it was time to start working on the bike. First I took off the skirts, and then the exhaust. Next up was draining the coolant.

Then it was time to pull off the top end and see how bad it was in there. Turns out it was much worse than I had expected. There was some pretty severe detonation going on. The may have been caused by the lack of enough coolant.

I also checked out the crank, and it doesn't spin as free as it should. So the engine is going to have to come out, and the cases split. This means more time, and decisions on how I want to go about setting up this bike.

The one good thing about this is that I now know what the loss of power feels like when the bike is detonating.

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Prepping the removal of the engine mounting bolts.

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Disconnecting the ignition, ground strap, and starter. It also helps to remove the coil providing extra room for the extraction.

Remove the carb, and intake manifold.

Remove the transmission vent hose, and turn the vent spigot in towards the front of the engine.

Another important trick into loosen up the swing arm pivot. Then rotate the rear mount up. Later when moving the engine out it can be rotated down allowing a much cleaner extraction.

With that done you can lift up the engine from the left side of the bike. Rotate the front of the engine to the right, and pull the rear of it out the left side. It's a tight fit, but with these little tricks it work out quite nicely without a need to ding up the frame.

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I got a lot done tonight, but probably wont have time to clean up the photos for posting tonight. Those of you that have seen this before though know what to expect!

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With the engine pulled out of the bike it was time to clean it up a bit, and then open it up.

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Got the case matching done.

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While at Treats today I popped the ProRace piston and ring on the scale—78g.

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I noticed the bearing at the output shaft was a little gritty. Ed confirmed that it's not worth messing around so that needs to be replaced too. Hopefully I can find a bearing and seal at an auto parts store. Otherwise I'll have to wait until Monday to start putting things back together.

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On the Derbi Euro2 engine the output and primary shaft bearings and seals are

Bearings: 6203, 6203ZE, HK1412

Seal: 17-35-7