Starting the hobby again... Need some advice.

[zack_novak]

Well, I haven't been into these little bikes for a year or two and it feels like forever. I have been all tied up with moving and other hobbies. Unfortunately a lack of time and extra moola has left my bikes sitting in the garage in need of repair and maintenance.

My HK1 happened to take a turn for the worst before she was parked. The oil drain was cracked at the case and spewed oil, and it needed a tranny repair. My local shop diagnosed the shifting/tranny problem as the shift forks. I pretty much decided to go ahead and repair both the shift forks and the right side engine half. Sure enough, I scored a cheap bottom end from a parts bike and ripped the shift forks/engine half off of it. As of now, I have my original engine and the necessary parts.

I need advice on how I should go about doing the parts swap. What I mean by that is: What would be the most efficient way to do it and what parts will I need? Gaskets, screw kits, misc. parts, etc. All of that I need to put together and get an order going on dratv. By the way, this has the 88cc Big bore on it, so I believe the only different gasket would be for the head/cylinder.

All advice is appreciated. Thanks in advance for any info.

 

[theraymondguy]

Several ways to skin this cat.

Build a box to support the engine (laid on it's LHS) - I build mine 6 3/4 x 8 3/4" (inside measurements) out of 2 x 6" (leaves lots of room for crankshaft).

Drain all fluids.
Thoroughly wash down frame and engine
Pull carburetor (disconnect throttle cable and let it hang) & exhaust
Tear down the top end
Pull off flywheel
Drop bottom end out of the frame

If you don't have a high flow oil pump you should. If you do or are going to, you'll need to open up the the restriction orifice in the rhs case (under the cylinder stud) to 2mm or 5/64".

You'll need a complete gasket kit (don't forget that the seals for the bottom end shafts are not included in most kits)
88cc cylinder head gasket
Cam chain, oil pump sprocket, idler and tensioner sprockets are pretty common for wear. New springs for the cam chain tensioner.
Impact driver with #2 and #3 phillips bits for the case and clutch/flywheel cover hardware- a left hand 3/16" drill bit for the stubborn ones.
Flywheel puller and clutch nut tool
A magnetic drain plug is highly recommended