Stakes

Got my bike in bits since I bought it as a botched but running machine (for 5 years!). When I bought it I drained the g/box oil and a small broken shim washer fell out. I suspect this was the #41 on the secondary shaft from the manual (I use the Evo 2010/11 manual which I have been told is relevant to the 2008 270 motor). I have a couple of questions. I am unsure of the direction of 1st gear on the secondary shaft (see photos - is it 1 or 2). Also I have a shim washer #4 on the primary shaft 20mm x 30mm x 0.5mm in the manual but mine measures 1.0mm thick?

With lifting the cylinder up you are also lifting all the ports and lifting the exhaust is counter productive to what you are trying to achieve so I guess thats why he went with the low compression head I guess. Also I sourced some bearings from my local bearing supplier for the bottom end. They are all the same as I removed, SKF Explorers and C3 where necessary. The mains are open with neither steel or plastic shields. The bearings I removed did have metal shields. Are these open bearings going to be ok or should I get metal shielded? The ones I have bought are 6206/C3 SKF.

Thanks for the fast reply. I'm pretty sure the crank seals were shot when I bought this bike as it would start, rev its tits off then cut out. The barrel looks good but the head has a lot of detonation marks. Maybe this was down to the crank seal or the squish was too tight. I'll try a 1.0mm base gasket and measure. I've read elsewhere that 1.0-1.5mm is correct. Which would you choose. I'm a 49yr young novice rider at trials and come from enduro and road racing. Great tip on the bearing slug. I'll turn a top hat bush hat sits inside a little. On the timing I read that the gap should be 7.0mm from the right side of the bolt / screw to the left side of the slot. Is that applicable to the 2008 270 - it would leave it pretty much near the middle? Would advancing be increasing the slot gap on the right (ie. turning the backplate anti-clockwise)?

Hi there, Just torn my REV 3 270 motor down for new bearings and seals and am going through other items whilst I wait for parts. I've never used the bike as it had a few issues when I bought it. I have a few questions please - some may be dumb but its been 10 yrs since I had a 2 stroke apart and a few brain cells have said rendex vous, if anyone can help: 1) Rings - My bike has a Vertex piston (I'm not sure whether this is the original make of piston) looks in good condition. When I push the rings into the barrel the 2 ring gaps measure up at 0.5 and 0.7. I've read in the evo manual that the gaps limit is 0.6mm. Do I leave or replace? And if I use as is should I put the smaller clearance at the top. 2) Does anyone know the dims to measure a 270 piston and also the 270 cylinder bore as the evo workshop manual only states 250 and 290 specs but am I right in thinking most of the 2008 motor is the same? 3) The stator backplate is slotted. How do I know the correct position? 4) When setting the squish with some soft solder to choose the base gasket (mine had 0.5mm) can I reuse the head gasket or is it once use only? 5) I've just fitted all new bearings in the cases and the manual says to heat the mains before fitting the crank. I'm worried that I will damage these expensive new crank seals. I can turn up a protective plug to drop in whilst heating but is heating necessary. I cant remember doing this on my old Honda RS race bikes years back? 6) The UK 270 has an extra flywheel weight. Should I refit this? Matt