Help with top end rebuild please

[pandp]

I have just bought another project but engine rebuilding is all new to me. I picked up a 2003 kawasaki eliminator 125, the bike itself is immaculate with only 4000 on the clock and not a blemish on it.

I was aware of the engine issues before buying it but just want to attempt to work on an engine. I have 90% rebuilt a Honda bros from boxes so not totally clueless with bikes, the bros just didn't need any major engine work doing.

Anyway i'll post some pics as these will show exactly what is wrong. The guy i bought it off told me Kawasaki do an oversized piston which apparently is what i'm going to need.

I'm just looking for help as to where to start, parts needed, special tools etc. Any help will be greatly appreciated.

https://i693.photobucket.com/albums/vv292/p71p/SAM_1439_zpse3fa794b.jpg
https://i693.photobucket.com/albums/vv292/p71p/SAM_1440_zps279b8452.jpg
https://i693.photobucket.com/albums/vv292/p71p/SAM_1441_zpsc547f838.jpg
https://i693.photobucket.com/albums/vv292/p71p/SAM_1442_zps3713f6a6.jpg

[Taught2BCauti...]

I think you will need to take the barrel and head to an engineering shop to have the re-boring done. They will probably be able to supply an oversized piston and rings to suit - but get a quote first.

I think you will need new valves, valve seats and probably valve guides aswell - and maybe even a head skim if it need much machining to get the combustion chamber looking like new again.

Check con rod, gudgeon pin and big-end bearings too whilst you are at it.

I would recommend a decent 3/8" drive socket set, torque wrench, a couple of extension drives, and a Universal Joint - and a piston ring clamp and valve spring compressor to help put it back together.

Nice man cave!
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Honda Varadero XL125(V8)
www.TheFutureIsHere.eu

[pandp]

Thanks very much for the info. I did wonder with the rebore. I think i'll pop it to my local engineering shop tomorrow and see what they say. Cheers.

My man cave is my escape lol. Built it last month and it's probably the best thing i ever bought lol.

[Ed Case]

Jesus wept it's certainly been 'Eliminated', were it mine it would be a 'bottom end' apart to see what damage or bits are down there, rebore if it's feasible to the barrel, and try and get a s/h head complete rather than spend time trying to salvage what you've got and buying valves/guides etc. Best of luck.

[stinkwheel]

Just to echo the above. That thing needs a full strip down.

It almost certainly has bits of metal all over the place inside the engine and a fair bit of aluminium swarf in the oilways. Can you account for all the bits of valve and piston?

Big and small ends will have taken a hammering. Every chance the conrod is bent.

Your head is pretty much scrap without some serious engineering work, new valve seats cutting etc.

In all seriousness, I'd be keeping my eye out for second hand motors on ebay. By the time you've replaced/reconditioned the head, bought a piston and gasket set, and had the barell rebored, you could've bought an engine that's known to work. Keep that one for spares.

What you really want is a crash write-off because what you have is a good rolling chassis and engine casings, the rest of the engine is questionable. Check the salvage companies.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Pete.]

I'll echo what Stinky says, there's a lot of stuff in that engine that's going to be questonable even if it looks ok. Crank, ends, rod will all have taken a beating.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Nobby the Bastard]

Wot Stinky said.

Don't bother rebuilding, get another engine. That's going to be a lot of work to rebuild and it's debatable that the cost is worth the effort, even for someone who knows what they are doing.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[pandp]

Cheers guys, it is a mess. I'm on the look out for another engine but i don't think they are that easy to find.

[Ed Case]

Gotta admit that another total 'lump' is the way to go. Realistically too much work/buggeration/expense involved to make it worthwhile.

[stevo as b4]

Would love to know how you blow a hole that huge in the crown of a 125cc nasp single?

Did the exhaust valve break at the stem? I can't figure out what else could have started the destruction?

For a bike like that, a second hand motor is the way to go!

I swapped a CG125 motor in a mates bike, when his original lump had a main bearing rumble. The engine was unknown, but with a good clean up, the original carb, and everything serviced inspected (oil/filter change, Valve clearance check, centrifugal oil filter clean out, and checking over the clutch plates) it eventually fired up and ran really well.

The old engine was stripped, and would have ideally needed 2x new main bearings, a set of piston rings and a bore hone, plus valves lapping in, and all new gaskets and seals. Not a huge job or £££'s but with no labour still more in parts than the second hand engine, and if paying for the re-build it would have been stupid money.

[A100man]

[Ed Case]

It's gotta be a valve head snapping off to do that amount of damage.

[Vincent]