ATV Florida Forum

Here are some photos of a bad Nikasil cylinder being bored to accept a cylinder sleeve.

The next pic is the fixture I made to hold the cylinder while boring. Photo three is the cylinder ready for boring. The fourth photo is after the first pass that essentially removed the old coating (very hard stuff)

Cylinder bored and ready for the sleeve.

Cylinder sleeve installed . .004 press fit (requires heating the cylinder to 400 deg to install the sleeve)

Finally the sleeve itself is bored and honed the deck is surfaced and the cylinder is ready for use.

.

You have to set up the piston with the new steal sleeve cylinder a little loser than the nikasil cylinder, to prevent the piston from sticking.

looks good to me matt, is that thing goin to spank the 450's :dunno.gif :dunno.gif

yes but only by .0005" . Factory calls for .0011~.0018 so I took the mean dimension of .00145 and added .0005 and made it .002" clearance. It is a Cast piston so they don't expand like a forged one and you can run tighter clearances.

I am sure it will since the rider is Paul and we know how superior his skills are.  ;)

Looking great Matt...it's no 400ex but the mud machine looks like it's going to make a return to a Motoplex near you soon.  ;D

so that goes to the green monster :dunno.gif

Yeap!

OH SNAP  ??? ??? ;D

Tinkered with the Arctic Cat a little this weekend.

A little worried about how blue the crank is on the left side shown in the picture above but the rod bearing feels good....Probably that freds oil Paul uses.

The picture above is what Paul believes to be the only real problem with the cat ( a bad spark plug) It is almost unrecognizable with all that Freds oil baked onto it. The exhaust valves and ports are also caked with oil and carbon build up. I cleaned up the valves with a wire wheel and did a basic port job to remove the build up from the ports. I then lapped the valves to the seats and cleaned the head gasket surface. I also was putting on new valve stem seals and discovered that 1 of the brand new seals was not made correct so now I am held up by a stupid $5.00 seal.

Nice work !

Yeah like I said...new plug should sort it out...plus a couple of quarts of Freds finest.

Its a good thing that you have been spending some time on the 525, you should be able to handle all the power Matt is going to put back in the Artic Cat....

That's what I was thinking, That will be paul's new mx bike.

 ;D ;D ;D ;D ;D ;D

wow!!!!   opowersports  made er shine like new!!!  this guy took care of business!!!  good work! ;)

You ever need your spark plug changed...this is your man.  8)

I heard he does chain adjustments as well.  ;)

While working on the Cat I started finding metal filings  in places it should not be. So a complete tear down started. I found a starter gear Idler boss half broken off a busted idler shaft and where the idler gear was eating into the engine case. New engine case is 993.00 so plan b was to try and salvage it, I think it may work.

Next pic is the old broken idler shaft at the bottom. The new larger diameter shaft to the right and the idler gear that has been bored for the new larger shaft.

Pictures of the welded up case with the boss re machined. Weld looks bad but welding cast aluminum sucks.

Picture of all idler gears in place with the new shaft installed. It looks like it should work....

Good work sir....very impressive.

Now did you get around to changing the plug yet?

Also I can't seem to find a Freds store for the oil, in Tampa  :-\

You far from Green Cove Springs???

Fred's 1940
1435 S. ORANGE AVENUE
GREEN COVE SPRINGS, FL 32043

We need to get a lot of seals and gaskets before we can work on changing the spark plug. I better never see freds oil in or near that quad or I will set it on fire. Only excuse I will possible accept is if you get water in it and use the freds oil just to flush it out.
Also need a new battery and starter.

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nice work!!!!!!!    way to git er dunn!!!!!!!!! ;) ;) ;) ;) ;) ;)

Nice work matt you da man!!!

crazy are you going to have that thing done in time for Paul to break it on Labor day?????

If the parts will show up in time. For some reason this has been the hardest bike to get parts for in a timely fashion. I even paid for express shipping on the most recent order and still no parts yet.  >:(

In fact this is what I got for an email from them

Order UpdateYour Order: UJ8B311
Customer Service: 1-877-511-BIKE
Matthew,

One of the items in your order UJ8B311 had to be ordered from an alternate warehouse due to availability. As a result, the item(s) will be delayed 1-4 business days.
The remainder of your order has been processed and will be shipped when the delayed items arrive. Your original quoted shipping cost will not change.

Cross-Shipped Items:
Item NameQuantityTotal Price
O RING,WTR PMP1$4.59

Our advanced fulfillment system allows BikeBandit.com to pull inventory from multiple warehouses across the United States. This means that when you order from BikeBandit.com there's less of a chance that you will experience long delays and your parts will be delivered right to your door!
If you have any questions about your order, please call 1-877-511-BIKE (2453) or log into our LiveChat to speak with one of our representatives.
Thank you for choosing BikeBandit.com!
The BikeBandit.com Customer Support Team
1-877-511-BIKE (2453)
Mon - Thu 5:00 AM - 7:00 PM PST
Fri 5:00 AM - 6:00 PM PST
Sat - Sun 7:00 AM - 4:00 PM PST



How do you like the part in red even though they are gonna delay shipping the bulk of the order for a 5.00 part they are still going to charge me the express shipping price.  >:( >:(

thats so nice of them that they are still going to express ship your stuff out.... 6 months after you order it

Well I have a complete engine ready to go back into the bike. I however have found about 20 other issues with the Quad some will be addressed now and some at a later date.

Hey Paul...I am not sure but I think I figured out what is wrong with your 4wd.

 :o :o :o :o :o :o

Whats wrong with that

Dude screw bike bandit. cheapcycleparts.com Theyre cheaper than bikebandit and most times the parts arrive before the shipping status changes.

I use cheapcycleparts.com too... Cheap.

Well that didnt last long! The cat is down again! Way to break it Paul.  ;)

no sh*t. what happened now?

Matt thinks that weld didnt hold. He tried but may need new case. :'(

until there is a bike that can outlast paul they are all inferior



I think the golf cart is the only thing that he keeps running  :R :R :R

only paul.

Now that I think about it I didnt see the golf cart at all this weekend  :o

Nothing wrong with it, I had a smorgasbord of things to ride this weekend.

Everything I own except the Arctic Cat runs great, the only thing that needs some attention is the cat and quite frankly, if you buy a 5 yo bike that has been mudded to death and don't expect it to have a few problems, you are going to have a life full of disappointments  ;D

Have not tore into it yet but the Cat is not Paul's fault before the rebuild or after most likely just a crappy mechanic before he bought it and possibly now.  :'(

You quit on me  :o

who said I quit, I will keep working on it till it is fixed or destroyed beyond repair
 ;)

You sir. You said I most likely had a crappy mechanic now, well sir, you must have handed me off to another...cause you iz aces in my book. I even got you an assistant










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Dayum!!!!!



He ain't gettin nothin done with that handling his tools!!!!!