2007 RMZ 250 Complete engine rebuild
Mar29

2007 RMZ 250 Complete engine rebuild

This bike was brought to me with the cases split and all parts in a boxes.  From the beginning, I had my doubts about being able to safely put it all back together since I was not present for the disassembly.  It took a long time and a lot of replacement parts, but it finally started to take shape.  I had to start with the service manual and follow it step by step while taking notes.  Fortunately, Suzuki service manuals are in my...

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2005 CRF 450R Supermoto
Aug02

2005 CRF 450R Supermoto

I decided to trade my long-loved Husky for this CRF 450R Supermoto.  It has many nice upgrades on it, however it is definitely in need of some TLC and service.  The most attractive part of this bike is that it is TAGGED!  It may not seem like such an amazing thing, but in the state of NC, it is near impossible to tag a bike that started life as an off-road only machine.  This bike came with a clear VA title.  Once the vehicle has been...

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03 KX125 top end rebuild
Jan12

03 KX125 top end rebuild

This 125 belongs to one of my regular customers.  Over the last year, I have installed a new clutch, trued wheels, replaced fork seals, re-packed the silencer, etc.  Recently the owner had accidentally put non-mixed fuel in the tank and ran it for a while. The pictures show the galling of the piston and the cylinder.  This may have been caused by the non-mixed fuel.  I removed the seat, tank, exhaust,  and  radiators to access the...

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Jeep TJ Build up
Jan12

Jeep TJ Build up

This doesn’t really fit the site, but I have been having fun building up a jeep I recently got. It is a 97 TJ Wrangler SE with a 2.5l 4 banger.  It was bone stock when I got it, but I have since installed a 4″ rough country short -arm lift, a set of 15″ rock crawler wheels with 33×12.50 Maxxis Mudders.  I also fabricated some control arm bracket braces, sway bar quick disconnects, and installed extended brake...

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Powder coating rear sets

Here are some rear sets that a customer wanted powder coated.  We decided to go with flat black.  He also wanted to have the fasteners coated.  I took a small piece of steel plate and drilled and tapped threads into it so I could thread the bolts and screws into the steel and have them stay put while they were sandblasted, coated, and baked.  When coating aluminum, it is important that the item be “de-gassed” prior to...

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