Crusty Crank Area

[Chakka]

This is a look inside the crank area of my 175 engine.

http://photobucket.com/albums/b60/chakka141/1975%20Jackpiner/?action=view¤t=DSCF0058.jpg

Is there a cure availible for this pitting? Perhaps some epoxy product? when I split the cases it appears on it's last ride this engine ingested about 2lbs of mud which was left to sit, hence the pitting. I cleaned this area with a toothbrush and kerosene so the mud is removed in the photo. I took a whole series of pictures of the tear down...this project will make a great before and after....if I can get through it!

http://photobucket.com/albums/b60/chakka141/1975%20Jackpiner/

Chris

[firstturn]

Chris,
  I am not a expert on the KTM engines, but the nice thing about 2 stroke engines is the transmission is separate from the transmission so your tranny is OK.  I think the cases are fixable.  Just bead blast them first and see what you have to work with.  A lot of clean up and a new rod kit along with a fresh top end and you should be good to go....now there is a lot of work between the repair and good to go, but unless you find a donor engine yours will clean up in my book.  The rest of the bike looks great.  Nice bike in the background.  Just my take.

Ron Carbaugh

[Chakka]

Ron,

Thanks for the input. I've never been afraid of hard work and this Jackpiner tests me at every turn. Little by little it's coming around and I am determined to win this fight. I will get the bead blasting done and see how smooth it is. I thought that area might have some critical tolerances that needed to be maintained. You are right about the transmission area; it's super clean and looked new when I cleaned out the old sludge. Thanks for the comments on the background bike. The Six Day was my first project, the frame with red airbox was slated to be a Berkshire until I stumbled across a Monark 125GS engine.

Chris

[slvrbrdfxr]

Chris,
I think the stuff you are looking for to seal the cases after bead blasting is Red Glyptal. There is a thread on page 3 of the "For Sale/Wanted" section about it. Pretty sure that's what Kip sprayed on mine when he did the bottom end.
Dave

[Chakka]

Thanks Dave,
I just googled it and printed the spec sheet. It does look like the right stuff for that application.
Chris

[Lew Mayer]

They are some ugly lookin' cases.[:0]

Lew Mayer

[Chakka]

Tell me about it Lew, I spent an afternoon cleaning them up. Lots and lots of engine cleaner, elbow grease and they look presentable with the exception of the crank area. The cylinder ports even had corroded magnesium from the lower unit in them. Luckily those cleaned up nice

Chris

[hrbay]

This bike was a prototype submersible that it's previous owner forgot to install the snorkel on. Wow, these are the projects that try mens souls. I had a 125Puch(non magnesium) that was nearly as bad and it needed a sleeve too! The cleanup can be followed by a coating of some sort, I used Hysol ea934(Loctite company) commercial grade epoxy, and made sure all seal surfaces were squared after curing. Keep in mind you are saving one that quite literally was dead without your help. Take some after shots too. Cool project.

GC

[Speedy]

quote:Originally posted by firstturn

Chris,
  I am not a expert on the KTM engines, but the nice thing about 2 stroke engines is the transmission is separate from the transmission so your tranny is OK.  I think the cases are fixable.  Just bead blast them first and see what you have to work with.  A lot of clean up and a new rod kit along with a fresh top end and you should be good to go....now there is a lot of work between the repair and good to go, but unless you find a donor engine yours will clean up in my book.  The rest of the bike looks great.  Nice bike in the background.  Just my take.

Yeaaaa,..RON,..age is creaping up on you right???
on 2 stroke the transmission is separat from the transmission,...
Now lets see...4 strokers do NOT have the transmissions separated from the transmission,...?how about Diesel engines?:D:D
Anyway,...this engine is a real project thats for sure,...
I had a few like that in my life,..If you empty your local PONDS you will find more like this vehicles in there,..[}:)][V][?]
Speedy------>>>>>>>


Ron Carbaugh

Helmut Clasen KTM
162 Hillcrest Ave
L9H 4Y3
Dundas Ontario Canada
Ph.905-627-5349
[email protected]
http://speedy_c.tripod.com
Sachs MC-GS 250-7A reeds
Hercules 350-7A 77
Hercules 250-7A 76
Hercules 250 GS 7A 77
Zuendapp 125 GS
KTM 200 EXC 2003
KTM DUKE 96 Spec.

[don howard]

Chakka.   Gee that looks like something I would and did find on my DKW. Tell me how did you get the piston out of the jug? I had to drill mine out , just wondering. The rest of your bikes are just the best that i have seen.   good luck    Don Howard

[Chakka]

Thanks Don,

The other bikes were fun to rebuild but nowhere near the challenge of my little blue "problem child" Jackpiner. I think it was owned by a former U-Boat captain who had no problem diving deep into mud holes.

To remove the cylinder I pulled the spark plug and poured in penetrating oil there and around the studs. Heating the studs with a torch facilitated removal of the head. I think a weekend of applying the penetrating and allowing it to work did the trick. Eventually I was able to work the cylinder off the stuck piston.

As luck would have it I just found a 76' Jackpiner with a better engine and a pipe (mine was rusted through at the head pipe). I purchased it and will be going to get the bike tonight. The engine in the pictures will eventually be rebuilt as a spare but now I can take my time and really do it right.
Chris