After the first couple of sessions at the track, when I got back to the pits coolant pissed out and then I noticed that the temp gauge was flashing HI. At first I thought it might just be an air pocket from not bleeding the system properly when I swapped […]
Maintenance
KYB Fork Protector
One of the fork protectors was missing off the 2007 YZ250F and they are about $25 for a new one. I figured I’d design and print one and see if it would stay in place on the track. Quick model drawn up in Onshape. Printed in PLA for now simply […]
48mm Fork Seal Sliders
Coincidentally, both sets of forks on my dirt bikes were 48mm and both needed new seals. I drew up these seal sliders incorporating a groove in the OD that was intended for a tie wrap to hold the two halves together. Most often these are made from metal that has […]
KTM Shock Spring Adjust Tool
After the success with the fork cap wrench I figured that I might be able to make a strong enough tool to adjust the rear shock spring, when setting the sag for example. The first tool was a little bit long so the end would foul the airbox and the […]
Yamaha KYB Fork Cap Tools
I needed to replace the fork seals on my 07 YZ250F and didn’t have the special wrench for undoing the fork caps so I designed this tool to be 3D printed. It took a few iterations to get the design strong enough but I was successfully able to loosen both […]
Damaged Aluminum Thread Repair
When working on used vehicles it is almost certain that you will run into a damaged thread situation at some point, especially with threads in aluminum – it doesn’t take a huge amount of force to strip threads in aluminum. The latest issue for me is stripped threads in the […]
Dirt Bike – Repair Dent in Exhaust
2 Stroke Through a recent trade, a KTM 125sx was acquired with a huge dent in the exhaust. Dents like this, not usually as bad are very common on these exhaust expansion chambers and while the bike might seem to run ok, a dent this size must be having an adverse […]
Kawasaki KX100 – Replace Gear Change Shaft
Replace Gear Change Shaft on a 2001 Kawasaki KX100 On the kids’ KX100 the gear change shaft sheared at the neck and needed to be replaced. I wasn’t sure whether I would need to split the engine cases but as it turns out, the engine doesn’t even need to be […]
Dirt Bike Wheel Repair
Wheel Repair on a 1992 Suzuki RM125 Difficulty: MediumRecommended Tools: Vice, spoke key, can of lubricant with straw, chalk When I got my bike, the wheels had certainly taken a bit of a beating, the front wheel bearings were shot, both rims were buckled and the front rim also had […]
Dirt Bike – Electrical Troubleshooting
Electrical Troubleshooting on a 1992 Suzuki RM125 Difficulty: Medium, can be tough!Warning: High electric currents can be dangerous, take appropriate precautionsRecommended Tools: Multimeter Dirt bike electrical systems are relatively simple and yet there is a lot of confusion around that can make troubleshooting tough. The 1992 Suzuki RM125 that I […]