Sumotrack rebuild

[Rat_ranger]

So some of you probably remember this bike. And after it broke on the dyno it ended up sitting a long time. At first it was to save up for a Hoo's 700cc top end, then I moved from WA to OK, and when I put the top end on I found the throttle bodies stuck. This was the last straw and I lost all motivation on it.

Fast forward and I decided it was time to ressurect the bike and fix a few things I never liked. 1. Cheap gps speedo is being replaced by a motoscope mini. 2. The exhaust is changing to a high pipe. 3. New headlight that'll actually allow riding at night.

1. I have the motoscope and already made a mount for it, it's what kicked this off. I was originally going to put it on my DRZ, but changed my mind.

2. I have almost finished fab work on the high pipes. I used pictures of the jemco exhaust to guide the fab work.

3. I should have the new headlights tomorrow to start figuring out the mounts.

The frame will need to be re powdercoated after I finish everything. Fuel lines have gotten super stiff. Brake hoses have yellowed. So it's a fair bit of work to fix the neglect.

 

[Rider52]

You did a great job on the exhaust. I had Jimco on one of XS650s and I thought your exhaust was Jimco!

 

[Rat_ranger]

You did a great job on the exhaust. I had Jimco on one of XS650s and I thought your exhaust was Jimco!

Thanks! I looked at pictures of jemco pipes to get rough measurements and ideas on angles. I started with cones from cone engineering and tube from summit. I'm pretty happy with how it looks. I plan on getting it coated by jet hot. I'm going to do some more work on the frame, finish up heat shields then tear down for fresh powder coat and fix some wiring.

 

[Rat_ranger]

Headlight mount being worked on. Going to get a new numberplate to put on the front.

 

[doc_rot]

Exhaust turned out super nice! I recently bought these for blending out welds and providing a uniform finish on round tubes - kicking my self for not buying them sooner.

Astro Pneumatic 3039 Tube & Weld Belt Finish Sander (3/4" x 20.5") with Belts | eBay

Adjustable 3/4 x 20.5″ air belt file for cleaning, weld prep and material removal on tubing or any radiused work piece. Adjust roller position to create slack in the belt that allows for sanding along curved surfaces.

www.ebay.com

Belt Sander Attachment Bracket Angle Grinder Pipe Tube Aluminum Alloy Support | eBay

Find many great new & used options and get the best deals for Belt Sander Attachment Bracket Angle Grinder Pipe Tube Aluminum Alloy Support at the best online prices at eBay! Free shipping for many products!

www.ebay.com

 

[Rat_ranger]

Thanks, I've wanted a tube sander for a while. I just haven't been able to bring myself to buy one. Name brand ones start at like $300, the chinese ones are around $150, and I hadn't seen anyone test the angle grinder attachment.

 

[doc_rot]

Like you i couldn't justify the expense of the whole tube sander since I use it so rarely, but the attachment works well and only $40! I don't think I could make one for much less than that so I opted to by one. I used it to blend the welds on the mid pipe on my KZ1000 which i posted here recently. The smaller belt sander is really good for the internal radius bends and is more precise when sanding back the weld bead initially. I was using them both this weekend to prep tube for My SV650 project.

 

[Rat_ranger]

Yeah. I'll get one one of the attachments. I'm glad the chinese companies are making better tools now as it makes some of the better ones come down in price now that there is competition.

On cyber monday homedepot had the milwaukee m12 die grinder on sale for $200 with 2 2.5ah batteries, a 5ah HO battery and a charger. It goes through the battery quick, but man is it useful. I wasn't willing to pay over $200 for a bare tool, but the sale was too good to pass up.

 

[Rat_ranger]

Well, waiting on parts now. I planned on clearancing the clutch cover for the high ratio primary gears, pulled the oil pump and now I need more parts. Got a new cover and pump parts coming from ebay, I wonder if the oil pump contributed to the failure on the dyno.
Otherwise I'm saving up for all the bits from venhill to make custom throttle cables, and to send the pipes to jet hot for coating.

 

[ridesolo]

I've never seen or heard of an oil pump breaking like that.

 

[Rat_ranger]

I've never seen or heard of an oil pump breaking like that.

Yeah, not sure how it broke. It's pretty scraped up, but I don't know if that was the cause or an effect.

 

[ridesolo]

Yeah, not sure how it broke. It's pretty scraped up, but I don't know if that was the cause or an effect.

Sure hope there aren't pieces of it lingering in unfortunate places!

 

[Rat_ranger]

Sure hope there aren't pieces of it lingering in unfortunate places!

The engine has been split since it broke. So it's been cleaned pretty well. I just had never pulled the oil pump.

 

[crazypj]

I've seen that happen twice but as I've worked on thousands of bikes over more than 50 years, it's still really unusual.
Both times it was due to bearing damage which was not cleaned properly.
I remember a Honda where clutch hadn't been fitted properly and bearing cage was damaged, ( I suspect someone poked at it with a screwdriver or pick?) piece about 3mm x1mm had gone through gears got squished flat then through damaged oil pick up. The other was an XS where piston broke up, rod was bent sideways and got ground by starter ring gear on crank (no idea how that happened, it's how I got a 'running on one, needs carb cleaning' XS cheap)
Broken pick up strainer is very common on XS so something similar probably happened on yours?

 

[Rat_ranger]

I've seen that happen twice but as I've worked on thousands of bikes over more than 50 years, it's still really unusual.
Both times it was due to bearing damage which was not cleaned properly.
I remember a Honda where clutch hadn't been fitted properly and bearing cage was damaged, ( I suspect someone poked at it with a screwdriver or pick?) piece about 3mm x1mm had gone through gears got squished flat then through damaged oil pick up. The other was an XS where piston broke up, rod was bent sideways and got ground by starter ring gear on crank (no idea how that happened, it's how I got a 'running on one, needs carb cleaning' XS cheap)
Broken pick up strainer is very common on XS so something similar probably happened on yours?

I never did find the failed wrist pin circlip. So it's possible.

 

[Rat_ranger]

A little progress. "New" side cover and oil pump are here. Clearanced side cover for the high ratio primary gears. Going to vapor blast it before use.
Also finally made the clamps for the exhaust. Used stainless packing strap to make them. Next I need to make the permanent hanger.

 

[Luugo86]

Glad to see this bike again!

 

[Rat_ranger]

Glad to see this bike again!

Thanks, hopefully I'll have it on the road this summer. Depends on how many setbacks I run into. Went to go to work today and had a flat on my DRZ, and not only did it put a hole in the tire but it punched lots of holes in the tubeless conversion. I wish I could track down who dropped it and make them pay for the repairs.

 

[Rat_ranger]

New exhaust hanger has been fabricated, pipes are off being coated, and carbs showed up from the UK. Switching to carbs since at some point in the move half way across the country and years of storage the ECU got water in it.

 

[Rat_ranger]

Almost done with the spin on filter adapter.