One more tid-bit of advice... Don't just let any machine shop do the inserts, it might appear to be a simple process, but I learned the hard way on this one, and ended up ruining a set of cases taking the 'cheap' route.
If the inserts are not done correctly, the case will crack out around the newly inserted sleeve. Shop around and find a shop/price that you can live with and send them off... making sure that the shop has done so many of these that they could do it in their sleep.

 

I'll ask around here in Ireland first surely some other bikes have a similar problem! so I might be lucky and find someone who does it.

 

Great news the cases already have the inserts! This should speed things up.

 

hey i got a pint of bacardi 151, u wanna mx up sum drinks?

 

I'll excuse you considering you'r name. But on a serious note I have no desire to drink, I could get all the alcohol I want (especially in Ireland) but I don't see a point in it its a waste of money. Anyway I found my own way of gettin rid of money,quads LOL.

 

so weedman smoke bud eh? by the way ill take you up on the bacardi i have my coke right here. lol

 

Hey emerald i know how your feeling with getting the zilla running,when i bought my 87 250--EVERYTHING was broke ----cracked cylinder sleave/damaged cylinder deck/stripped plug threads,bad crank bearings and seals,bad 2nd gear,bad clutch,bad shift forks,bad balancer bearings,bad shifter shaft,unuseable crankshaft,broken reed boot,my exhaust valve was broken,countless stripped bolts,no rear fender. ANd the first time i got it together it locked up!!! (to lean)---------------but in the end i have a very fast reliable really light quad,just do the work and in the end youll be glad you did!

 

Just said I'd keep you updated, well I have most my engine reassembled I only have to put on the clutch basket and the piston. Things didn't turn out too bad. And I got great experience from doing it myself I never thought I could split the cases myself!

 

Well I started my zilla last night and today, I just need to tune it in. Man this thing has way more compresson than before, the compression must have been low before the rebuild, cause now the kick start barley moves when I stand on it. I am findin it hard to get used to kickin her like before, and today it kicked back and split my sole on my boot and that did HURT i'm still limpin. Still its great to hear her roar again!!!!!

 

Good work!

Much more satisfying when you do the work yourself eh?