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Indy 400 Motor Rebuild? - Looking into rebuilding top end of my '89 Indy started by PULLaris400
May 28th 2009 at 8:03 AM
 
PULLaris400
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Location: Cumberland, Maine
Current Sled: Indy 400 Mod Sled
 
 
As the title says...what do ya'll think? The speedo has been broken for several years, and it reads almost 4000...I was thinking that it might time for a top end rebuild.

I know alot of people say if it ain't broken don't fix it, but I'm into preventative maintenance and it seems a shame to redo the suspension, track, and body without touching the motor. I ride alot alone, and can't really afford to have my motor die 50 miles into the woods.

I already deleted oil injection with my own homemade plate, and I think I should rebuild before I blow it up and put a hole in the block. If you look at the piston through the carb mount on the right side it looks like there is some scoring or black carbon streaks or something like that.

Looks like a kit to do gaskets, rings, pistons, clips, etc. is pretty cheap, probably well worth not being stranded.

I was wondering if someone can school me on overbore. http://cgi.ebay.com/ebaymotors/84-88-91-...dZViewItem I saw this kit, and some others, but it looks like it only comes with one piston? Anyhow...do I want a size up here to accommodate for wear? I'd need to get it bored out at a machine shop, right? Anyone know of a comprehensive kit with both pistons, etc?

This would be my first motor rebuild, but I think if I take my time I can get it done right with all your help, of course.

Thanks!

Jesse




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June 1st 2009 at 9:48 AM
 
PULLaris400
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A few questions:

I gouged up the bottom of the cylinder block where the base gasket goes taking it apart. It is spotlessly cleaned and I wet sanded a little bit but there are still some fairly deep dings. Looks to me like I could make a gasket seal there though, with some indian head stuff and making sure to fill the gouges with goo. Am I misleading myself, would I have to sand it until it was a perfect surface like the heads? Wouldn't this cause other problems, taking off that much material? I can post some pictures up in a bit too.

Next - can a dealer measure the pistons and cylinders for me, and tell me if I can use std. size new pistons/rings?? Also, would they be able to hone it for me? Any ideas on price?


Thanks for your help, JD has been real knowledgeable in the past, maybe he'll chime in.


Jesse




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June 7th 2009 at 5:34 PM
 
AHood
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did you pry the cylinder off with a screw driver? if its over 5000+ miles you probably need to go at least first oversize. dont try and just stick stock size in there hone or not.




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June 8th 2009 at 8:56 PM
 
PULLaris400
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Yea...got it honed and measured. Need oversize, so I ordered the .010 over with new rings, clips, pins, gaskets, etc.

Yea I had to pry it off with a screwdriver...but I read around some people say that the gaskets must be installed dry? I know the dings could be filled with some goo, and someone else said epoxy and sand the dings then do dry gasket install. Can I use Indian Head?? Someone must know.




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June 11th 2009 at 10:49 PM
 
PULLaris400
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Wow...maybe everyone just thinks I'm crazy rebuilding this old motor. No input on gasket sealant??




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June 16th 2009 at 7:36 AM
 
PULLaris400
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Ok. Progress has been made. I'll use the Loctite 515 sealer and klean/prime, as that seems to be the newer version of what my shop book suggests.

New problem:




So I'm assuming I can't use this flywheel again? Or am I still safe? Anybody know of a used flywheel? The stamped number is FP5487.




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June 29th 2009 at 4:02 PM
 
PULLaris400
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To the top....still need help w/ flywheel.




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June 29th 2009 at 4:08 PM
 
THE_Norwegian
:)
THE_Norwegian got some SLP powder pro skis in the mail today :-D.
Updated Friday at 5:32 PM
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whats wrong with the flywheel ? :) cant see anything wrong...





* XCR 440 *

"I`m not picking my nose.. I´m porting my head!"

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July 10th 2009 at 4:50 PM
 
PULLaris400
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Those cracks can lead to separation of magnets = big trouble.




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July 21st 2009 at 3:36 AM
 
1SethW
Im not Judging... I'm just sayin
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Too bad your not in minnesota i have stock piles of parts for those old Fujis I pretty sure i even have a few complete ones!!



Thanks,
Seth W

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