And so it begins (F11 rebuild)

aaron7 · 01-16-2006

Well, started on the bike today. Everything is stuck. Not sure if it's the cold or rust, but the carb, brakes, etc were all stuck!

Today me and a friend took the carb off (not too bad inside, choke seized, but aren't they all?), head off (piston looks bad, as do the walls), outer casing off (clutch worm gear needed grease BAD, oil pump looks good), and the exhaust off (still has all the insides!)

Found some bad problems though. The wrist pin on the piston is really... really worn. If you spin the crank back and forth (with the flywheel) the piston knocks. That's ok, I wanted to go a little bigger anyways! The crank bearings are also shot. You can move the crank up and down a little! The walls are really gouged... probably run without oil or something.

So the motor is coming out! We'll replace all the gaskets and bearings and clean it up nice. I'm hunting for a carb rebuiild kit and an engine gasket set as we speak.

I'll keep everyone posted!

Gunjji · 01-17-2006

Here is a carb rebuild kit for a F11

And here is a patch you can put on your jacket

F 11 engine side case screws

F 11 Levers

New Battery for a F 11

F11 footpegs

F 11 Repair Manual

F 11 Piston Kit

F 11 Clutch springs

F 11 Wheel Bearings

2 Pages of stuff, engine covers, gaskets, ect...

And something for Inspiration

Good Luck bro, keep us posted

aaron7 · 01-18-2006

Anyone know if they make an overbore kit that will fit this motor? After taking the motor out and removing the jug and piston, I see that there are some pretty good grooves on them! Not sure if just a honing will fix it.

Also, I need the whole engine gasket kit, as it is coming entirely apart for all new bearings. Any ideas?

I'll take pictures soon as I can!

KDXGarage · 01-19-2006

WOW! What a project! Good luck with it!

aaron7 · 02-11-2006

I think the bike looks better in green, don't you?

Aftermarket foot pegs (one was broken off and they were the old rubber style)

Some of the new parts; bearings, oil seals, gaskets, .60 Wiseco piston, side cover, etc.

.60 over cylinder... doesn't it just look beautiful?

Fully rebuilt carb (bought Kawasaki kit, came with nearly nothing in it! Bought Keyster kit and was much happier)

The main reason for the entire rebuild (nice crack there, and looks like this poor bike was run with a bad oil pump or no oil!)

KDXGarage · 02-11-2006

Hey, all right! Coming right along! Great job!

Gunjji · 02-12-2006

Yeah, very impressive... Did you buy the green tank/fenders?
Looks great, cant wait to see it completed!!!

aaron7 · 02-12-2006

Yah, I gota package deal of the fenders and tank. There were NOS ones on ebay, but the auction ended for $600 for the tank, and about $180 for each fender!

aaron7 · 03-22-2006

Hit a snag... I can't find a connecting rod or thrust washers... that's all I need to complete the bike!

ElmerFudd · 03-22-2006

The connecting rod is no good?

aaron7 · 03-22-2006

No, the upper bearing ate away at it too much and the new bearing doesnt seat right :/

ElmerFudd · 04-04-2006

Did you ever find a connecting rod?

aaron7 · 05-04-2006

Still can't find a rod or thrust washers

KXmanDan · 05-04-2006

I don't know if this will help but maybe you should call a dealer and ask for this part number 13044-023 this is the connecting rod set, or this 13036-037 for the crank and connecting rod set. This all I can find! Hope this helps.

aaron7 · 05-04-2006

Thanks for the numbers, but I have called EVERY dealer... that rod set was discontinued in 1983 I guess and no one has it.

KXmanDan · 05-04-2006

Quote:

Originally Posted by aaron7

Thanks for the numbers, but I have called EVERY dealer... that rod set was discontinued in 1983 I guess and no one has it.

Oh man that sucks.....there has to be someone that has it. You have to find a junker and by for parts.....that is if there are any junkers available.

KDXGarage · 05-05-2006

Well that stinks. As always, keep a close eye on eBay. MAYBE one will turn up for you. Good luck!

aaron7 · 05-24-2006

Found the last bearing I needed, got a new wrist pin, new thrust washers, and a mint used rod. I have to bring the crank assy to a shop to have it pressed... then the motor goes back together!

It's almost done!!

ElmerFudd · 05-24-2006

That's wicked, I'm glad to see you kept at it. Good job man, can't wait to see it done. Cause you know it's gonna run mint!

aaron7 · 05-24-2006

Better than mint... I found a local shop that does dyno tuning! Since the motor is .060 over and it's a 2 stroke I don't want to wreck it; so it will be tuned right away!

01-16-2006	#1 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	And so it begins (F11 rebuild) Well, started on the bike today. Everything is stuck. Not sure if it's the cold or rust, but the carb, brakes, etc were all stuck! Today me and a friend took the carb off (not too bad inside, choke seized, but aren't they all?), head off (piston looks bad, as do the walls), outer casing off (clutch worm gear needed grease BAD, oil pump looks good), and the exhaust off (still has all the insides!) Found some bad problems though. The wrist pin on the piston is really... really worn. If you spin the crank back and forth (with the flywheel) the piston knocks. That's ok, I wanted to go a little bigger anyways! The crank bearings are also shot. You can move the crank up and down a little! The walls are really gouged... probably run without oil or something. So the motor is coming out! We'll replace all the gaskets and bearings and clean it up nice. I'm hunting for a carb rebuiild kit and an engine gasket set as we speak. I'll keep everyone posted! __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100 Last edited by aaron7 : 02-11-2006 at 04:33 PM.

01-17-2006	#2 (permalink)
Gunjji I Hate Onions!!! Forum Supporter Join Date: Feb 2005 Location: South Jersey Posts: 320	Here is a carb rebuild kit for a F11 And here is a patch you can put on your jacket F 11 engine side case screws F 11 Levers New Battery for a F 11 F11 footpegs F 11 Repair Manual F 11 Piston Kit F 11 Clutch springs F 11 Wheel Bearings 2 Pages of stuff, engine covers, gaskets, ect... And something for Inspiration Good Luck bro, keep us posted __________________ My KX 250

01-18-2006	#3 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	Anyone know if they make an overbore kit that will fit this motor? After taking the motor out and removing the jug and piston, I see that there are some pretty good grooves on them! Not sure if just a honing will fix it. Also, I need the whole engine gasket kit, as it is coming entirely apart for all new bearings. Any ideas? I'll take pictures soon as I can! __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100

02-11-2006	#5 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	I think the bike looks better in green, don't you? Aftermarket foot pegs (one was broken off and they were the old rubber style) Some of the new parts; bearings, oil seals, gaskets, .60 Wiseco piston, side cover, etc. .60 over cylinder... doesn't it just look beautiful? Fully rebuilt carb (bought Kawasaki kit, came with nearly nothing in it! Bought Keyster kit and was much happier) The main reason for the entire rebuild (nice crack there, and looks like this poor bike was run with a bad oil pump or no oil!) __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100

02-12-2006	#7 (permalink)
Gunjji I Hate Onions!!! Forum Supporter Join Date: Feb 2005 Location: South Jersey Posts: 320	Yeah, very impressive... Did you buy the green tank/fenders? Looks great, cant wait to see it completed!!! __________________ My KX 250

01-19-2006	#4 (permalink)
KDXGarage Hey, lemme ride your bike BTK Expert Join Date: Dec 2005 Location: AL, USA Posts: 1,252	WOW! What a project! Good luck with it!

02-11-2006	#6 (permalink)
KDXGarage Hey, lemme ride your bike BTK Expert Join Date: Dec 2005 Location: AL, USA Posts: 1,252	Hey, all right! Coming right along! Great job!

02-12-2006	#8 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	Yah, I gota package deal of the fenders and tank. There were NOS ones on ebay, but the auction ended for $600 for the tank, and about $180 for each fender! __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100

03-22-2006	#9 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	Hit a snag... I can't find a connecting rod or thrust washers... that's all I need to complete the bike! __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100

03-22-2006	#10 (permalink)
ElmerFudd Powerband Crazy BTK Intermediate Join Date: Feb 2006 Location: NS, Canada Posts: 233	The connecting rod is no good? __________________ Power every second stroke is better then power every fouth!

03-22-2006	#11 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	No, the upper bearing ate away at it too much and the new bearing doesnt seat right :/ __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100

04-04-2006	#12 (permalink)
ElmerFudd Powerband Crazy BTK Intermediate Join Date: Feb 2006 Location: NS, Canada Posts: 233	Did you ever find a connecting rod? __________________ Power every second stroke is better then power every fouth!

05-04-2006	#13 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	Still can't find a rod or thrust washers __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100

05-04-2006	#14 (permalink)
KXmanDan Cruising In Fourth Gear BTK Intermediate Join Date: Mar 2006 Location: USA Mount Pleasant, Utah Posts: 219	I don't know if this will help but maybe you should call a dealer and ask for this part number 13044-023 this is the connecting rod set, or this 13036-037 for the crank and connecting rod set. This all I can find! Hope this helps. __________________ http://www.kawasaki.ca/motocross/KX2...s/05_KX250.jpg Last edited by KXmanDan : 05-04-2006 at 04:10 PM.

05-04-2006	#15 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	Thanks for the numbers, but I have called EVERY dealer... that rod set was discontinued in 1983 I guess and no one has it. __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100

05-05-2006	#17 (permalink)
KDXGarage Hey, lemme ride your bike BTK Expert Join Date: Dec 2005 Location: AL, USA Posts: 1,252	Well that stinks. As always, keep a close eye on eBay. MAYBE one will turn up for you. Good luck!

05-24-2006	#18 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	Found the last bearing I needed, got a new wrist pin, new thrust washers, and a mint used rod. I have to bring the crank assy to a shop to have it pressed... then the motor goes back together! It's almost done!! __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100

05-24-2006	#19 (permalink)
ElmerFudd Powerband Crazy BTK Intermediate Join Date: Feb 2006 Location: NS, Canada Posts: 233	That's wicked, I'm glad to see you kept at it. Good job man, can't wait to see it done. Cause you know it's gonna run mint! __________________ Power every second stroke is better then power every fouth!

05-24-2006	#20 (permalink)
aaron7 Foil Inspector BTK Beginner Join Date: Jan 2006 Location: MA Posts: 102	Better than mint... I found a local shop that does dyno tuning! Since the motor is .060 over and it's a 2 stroke I don't want to wreck it; so it will be tuned right away! __________________ 1973 Kawasaki F11 250cc 1974 Honda CB360 twin 1965 Honda C100

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