First ride for Keith after the resto. Decided the
stance was too narrow so ordered new tires with offset wheels.
Added LED lights front and rear. Thanks to Palmer
industries, Keith has a matching fuel jug as well. These two photos
taken February, 2009.
February 2010. The engine was tired and smoking so
we opted to overhaul it for the 2010 season. The cylinder had rust
pits and the intake valve was shot.
All the parts cleaned and ready for reassembly.
Transmission gears and crankshaft reinstalled in
the case. Sides of crank were tapered to lighten and I was able to
remove 183 grams. Lightening the crank and flywheel definitely
helped acceleration off idle. The new piston weighed in the same
within 1 gram of the old one so engine balance was not an issue.
Old piston right and new piston left. The new one
is 3mm (.120) oversize. Old piston is cast aluminum and the new
one is forged. Even though the new one is considerably larger
diameter, they weigh within one gram of each other.
Lightened the flywheel 50 grams and repainted it.
Discovered that it was possible to add 4th gear to
the Raptor by using the shift drum and gear from a late 80's Badger
or Champ 100. I found the parts on E-Bay really cheap. Keith's main
shaft is on the bottom and you can see his original gears. The far
left gear from the top set was added to Keith's setup and the lower
of the two shift drums was used. As you can see the channels for the
shift forks are machined a little further around to activate 4th
gear for a 1 to 1 final drive ratio.
Gears installed and case halves buttoned up. Got
ahead of myself and didn't get any photos of the inside gear
arrangement. rh photo shows the piston installed.