andersonj

Sodium Hydroxide works pretty good as long as you take precautions and wear good latex gloves (2x on each hand), goggles and a stainless wire brush. The stuff is easiest to find as drain cleaner, just read the back to make sure you don't buy some Al-Gore environmental do-goody stuff. Don't leave any aluminum parts submerged for more than 10-20 minutes as it will eat it away. Rinse off with water. I did this to my Sherco header and muffler (after the packing was removed) and it came out perfectly clean. J.

I'm interested in one of these but I don't have the luxury of trying one of the Shiros on for size since noone close carries them. Do they run large/small? What is your hat size (or head circumference) compared to the Shiro helmet size that you ended up with (s/m/l etc.)? Thanks, J.

Hopefully I can get some first hand advice on Saturday at the Columbus IN event. I work in Erlanger N.Ky, and live in the Milford/Loveland, NE Cinci. J.

Well, got the cylinder off tonight. Not that difficult after I took the electronics out and slid the radiator up out the way. Bore looks good, no scrapes or scratches. Honing marks are gone from the active stroke area however Piston is 1st bore 'A'. There was a fair amount of carbon build up on the piston (1/32"?). Got that all off and cleaned up. Also cleaned up the transfer ports, exhaust ports and the head. There was some dark brown discoloration below the two rings on the sides of the bore in line with the main transfer ports. Does this mean I am getting blow-by around the rings? Is this normal? Wondering if I should put in a new top end since its apart, that decision can wait though. My main area of concern is the cylinder studs. 3 of the 4 show some corrosion, particulary the front ones. I would say it is 'moderate surface rust'. I'm guessing because the water passage is at the front and at some time a small amount of water leaked to the stud area. I put "PB Blaster" penetrating spray on the threads before removing the nuts at the base of the cylinder and they came off pretty easily. Now my concern is when I replace the cylinder and torque down the nuts that I shear the studs. Sent some pictures to a number of cylinder repair places around the country. Only got one estimate back "probably less than $200". Still looking for a local, good quality (and cheaper) alternative. J.

Had a good chat with RYP this AM about my cylinder problem. Looks like it will be salvageable with some welding and machining. Going to pop off the cylinder and bring it to the local event in Columbus IN on Saturday for the RYP people to look at in person. Also working on finding a local source to do the work. Feeling a whole lot better that when I discovered the issue last night. Thanks to all. J.

I'm in Kentucky, USA. J.

Bill, Appreciate the reply. If only it was that simple. It's not the bolt thats snapped off but 1/2-3/4 of the boss on the cylinder. Basically a big aluminum chunk is missing. A bolt will thread into it, but I'm not sure how much clamping pressure it would have. i guess in theory the cylinder may be salvageable but removing it, welding up the boss, machining and re-tapping. Are there services in the US that do this type of thing? J.

OK, so a few weeks ago I bought what I thought was good condition older Sherco 2.5 as a starter bike to get into trials. Seller explained a local dealer had gone through the bike only a few months earlier and replaced head bearings, swingarm bearings etc. Being mechanically minded but not bike savvy I only gave the bike a superficial inspection. Sale was 'as is'. The really bad....took the muffler and center box off tonight to give a good cleaning and found the header loose....mmmm....closer inspection, only one bolt in the header flange....even worse the other lug in the cylinder head is half broken off.. cr*p. My 'good buy' just turned into a basket case. Not sure what to do at this point. I know a new cylinder is going to be mega $$$$. Maybe I should just cut my losses and sell it a project bike to the next guy. Anyone have even a guess at the cost of a cylinder, gaskets, piston? J.