Ever month our technical guru Ross McWatters helps confront the tough technical issues faced by our readers. Got a question you'd like to ask Dr Ross? Just send an email to drross@emap.com.au and prepare to be dazzled by his technical wizardry.
Surging Ahead - April 2008
Ian Lamb asks: I own an '03 Yamaha WR450F and have done about 2000km on a new barrel, piston and rings. To suit my Higashi pipe, I have fitted a DS needle set, four clips from the top and have drilled the airbox. The bike ran great up until about a month ago, when I noticed that at around 90km/h (with standard gearing) it's developed a rhythmic surge with constant throttle. Is this a jetting problem?
Dr Ross answers:Ian, the bike is running lean at that throttle setting. Mostly you would never notice this in normal off-road use where the throttle, gear and load is constantly changing, but when you ride on the road at a constant throttle and 90km/h, you probably only have it at quarter-throttle. These bikes where not made to be ridden this way and that is your issue. Vary your speed and throttle openings more and never think of it again because chasing it around with jetting will not be a fun task.
Loose Unit - April 2008
Rhys, email asks: The spokes on the back wheel of my '06 CRF450 have all gone loose. I tried to tighten them but now the wheel is a bit wobbly. Does this matter or should I get it done properly?
Dr Ross answers:Rhys, if your wheel has more than about 2mm run-out, you should really have it straightened out by a professional. Truing wheels is as much an art as a science; your local bike shop will be able to help.
Powerbland - April 2008
Daniel, email asks: I recently bought an '06 KTM 250SX, which doesn't seem to be hitting powerband when I give it full throttle. As I am used to riding older bikes, could it be that it's just because the transition to powerband is very smooth, or could something be worn?
Dr Ross answers:Daniel, the '06 KTM 250SX is a monster power-wise, and, if it is feeling unexciting, it must have a problem. Check the reeds for chipping and make sure the power-valve is operating correctly.
Trohan Horse - April 2008
Rohan Smith asks: I'm in the process of modernising an old warhorse – a '00 KTM 380EXC. I have read that the head was a common cause of the difficulty to jet them properly. I would like to get it machined to reset the squish and possibly lower the compression. Any suggestions on who to contact would be much appreciated.
Dr Ross answers:Rohan, having owned a '00 KTM 380EXC myself, I find it surprising that you are having trouble with the jetting as those issues were more of a problem on the earlier 360s and the first 380 model. This was largely due to compression that was too high for our fuel, and the tailpipe of the exhaust being too small. With your '00 model, I recommend you go to a 175 mainjet, 42 pilot jet and a DEL needle from Show and Go in SA on the middle clip. The FMF Fatty and matching muffler are also the go.
Off-Road Intentions - April 2008
MX Boy asks: What mods and regos are required to race a motocross bike like a YZ250F in the A4DE?
Dr Ross answers:MX Boy, you need a working headlight, tail-light, brake light and horn to qualify for an "off-road" or "rec" rego event. The requirements and limitations differ quite a bit from state to state. It is best to contact the organisers of the event to get the low-down on the local rego requirements. This year, the event is in the Gippsland region of Victoria, and you should be able to contact the organisers through Motorcycling Victoria's website http://www.motorcyclingvic.com.au/
Power-Up - April 2008
Valenzua asks: I own a '00 Honda XR100R that I want to race someday. At the moment, I have an FMF full exhaust on it but it bottoms out on big jumps. Where can I buy parts that will make it as fast as a CR80R?
Dr Ross answers:Sorry Valenzua, your XR100R will never be a match for a CR85 around a motocross track, and trying to upgrade it to be competitive will break the bank. Trade up to an 85cc because this is one dead-set case of ‘if you can't beat them, join them'.
Sooty Situation - April 2008
Troy Peterson asks: I recently purchased a new WR450F and, although the bike is great, I have noticed it has soot around the end of the pipe. Is this normal or is it running too rich?
Dr Ross answers:Troy, the black soot is actually a layer of burnt carbon that has been vented through the exhaust system. It's normal for a thin layer of carbon to cover parts of the engine and exhaust that come into contact with it. Normally, carbon does not present a problem. But, through the introduction of contaminants, such as oil or overly rich air/fuel ratios, carbon build-up can become excessive. This will reduce engine performance and require costly service or repairs. If it is just a layer and isn't building up, you don't have a problem.
Thirsty Work - April 2008
Adam asks: I have a KTM 525 and it really chews the fuel. The bike itself performs great, is very responsive and doesn't pop or fart. In an even mix of tight and open stuff, I generally hit reserve at about the 60-65km mark. Before I open up the carby, can you tell me what jetting, needle position, air/fuel mixture, etc I should set it to? The only mod it has is one of those Pro end-caps.
Dr Ross answers:Adam, your 525 is only fitted with a fairly small 9.5L fuel tank and, to make it worse, the EXC range has a decent-sized reserve, too. Most of the guys tell me they are getting 100-110km before they go dry. Some riders have fitted a leaner needle and one size smaller mainjet and report an improvement in fuel range. I would suggest you run a 182 mainjet, 42 pilot, OBDTR needle on the fourth clip from the top, and ride close to the car.
Shake 'n' Bake - March 2008
Pamela asks: My '06 Kawasaki KLX250S refuses to start when the temperature is below 7ºC, but on a 10ºC day or better it starts every time. Apparently many owners of the same model KLX have similar problems. I discovered that after rocking the bike side-to-side a few times it starts every time. Can you explain what's going on
Dr Ross answers:Pamela, the trouble is you're starting the KLX in extremely cold conditions. At 7-odd degrees you are pretty close to freezing and the fuel is icing in the jets. Some street models have their carbs fitted with a heating circuit to cut down on the problem. Next time it is really cold, keep the bike inside the house overnight and start it as soon as you wheel it out into the cold. My guess is it will start easily. The only real cure, other than keeping the carby and fuel warm, is to try running Avgas which has additives mixed into it for cold weather operation without icing.
Fatten 'er Up - March 2008
Todd asks: I've bought an '07 KTM 250EXC-F, which has done 26 hours of riding. It has good mid-to-top power but I'm looking to improve its bottom-end. Can you help?
Dr Ross answers:We've had plenty of experience with the 250EXC-F, and fitting the Akrapovic system with the long header pipe works well. We ran this set-up on Ben Kearney's Shift Motorex KTM race bikes. Replace the air filter frame with the one from the two-stroke model and you will find the power broader, smoother and more responsive.
Peed Off - March 2008
Dylan asks: My PeeWee 50 will be running perfect one moment and then it'll rev through the roof the next. I simply turn down the idle and it's okay again. But then it will drop right down and stall, so I have to turn it back up. What's the problem?
Dr Ross answers:Dylan, your PeeWee's carby probably has some wear or dirt in it. Strip down the carby and give it a thorough clean. Then blow it out with compressed air and check the needle and seat for wear.
Power Hungry - March 2008
Angry Mozzie asks: I was wondering if there are any upgrade kits for a '99 Yamaha DT230 that will give it a bit more get-up-and-go. I was thinking of either boring it out or fitting a different barrel. The only other suggestion I've been given is to put an old WR200 pipe on it. I'm guessing the pipe wouldn't be suitable for a DT230 as the exhaust port might be slightly bigger? Also, do you know of anyone who sells well-priced parts for the old girl?
Dr Ross answers:Angry, the DT230 has a similar motor to the older DT and WR200s, but the pipe is quite a different shape. Some pipes are available for the 230 in Japan (such as the YSR brand), although no one seems to distribute them here. My advice would be to find an English-speaking bike shop in Japan and see what they can do for you. Alternatively, getting a Pro Circuit WR200 system, and having someone modify it to fit your DT230,
will also liven your bike up quite a bit.
Don't Lose Your Head - March 2008
Jeff asks: I am the proud owner of an '02 YZ426F, which I fear may have a blown head gasket. I got the motor rebuilt 15 hours ago and it's run sweet since. A few rides ago, I noticed a lot of coolant coming out the radiator breather hose and that she was missing two of the nuts that help hold the cylinder on. After fitting new nuts, I went for a ride, but I think that the gasket has been damaged because it's still leaking fluid out the breather. Am I going to have to rip it down and put a new head gasket on or is there another option?
Dr Ross answers:Jeff, it would be advisable to get the head off and replace the gasket. If you are losing coolant, you are risking further engine damage through over-heating. If possible, have the head and cylinder gasket surfaces checked to make sure they are still flat. A sheet of glass and some wet-and-dry 600-grit sandpaper should do it.
Dirt Bike Dilemma - March 2008
Brett Morris, email asks: I'm 17 years old and looking forward to getting my motorcycle learner's license. I'm of average riding ability and want a 200-250cc easy-to-ride, low-maintenance, road-registered trailbike that won't bore me. My budget is around $3000. It will be great when I can finally hit the bush legally with Dad and his mates.
Dr Ross answers:Brett, with the road-going component of your planned riding, I would recommend a used KLX250 or 300. They are decent both on and off the road, and there's plenty of them around in your price range. A Yamaha TT-R250 or Suzuki DR250 would also give great value and are surprisingly good on the trails.
Lites Out - February 2008
Peter asks: My 2004 CRF250X always flattens batteries, even brand new ones. The worst part is, last week when it went flat, the bike stopped and refused to fire up, even with the kickstart. Thankfully, I was able to swap the battery with my son's CRF230 and it started straight away. I always put it on the charger between rides but it still goes flat. Any reason why I cant keep the battery charged, and why do you think it wouldn't even start with the kick-start?
Dr Ross answers:Peter, it sounds like your CRF isn't charging the battery. This could be due to a broken connection or a poor earth. First check that the battery is earthed correctly and then, with the bike at a high idle, put the battery on a multi-meter and check that the reading is over 13 volts. If there is no change in the reading after you've switched the bike off, your problem is with the generator or regulator. Best way to fix that is to drop it into the bike shop.
Ride Height - February 2008
Ramiro asks: My friend wants to give me his Yamaha TT-R90E, but as I'm 5'10” I will want to raise the ride height so it fits me better. Is there anyway to do it without spending an arm and a leg?
Dr Ross answers:Ramiro, just about every method of raising the little TT-R up will cost you money, and adversely affect the handling. I wouldn't recommend anything more than raising the seat height with some extra foam. A local upholsterer should be up for the job, or check out: www.australiancumfymotorcycleseats.com.au
Bike 4 Beer - February 2008
McNamara asks: I've just picked up a 1993 Yamaha AG200 (for two slabs of beer) that is hard to start and will conk out after 15 minutes. I've cleaned out the carby bowl, given it some new engine oil and a new fuel filter. What do you recommend I do next?
Dr Ross answers:McNamara, I would get at least one of those slabs back as you've been grossly overcharged! Take the re-possessed beer and the bike to a bike shop and get them to check the stator and coil.
Mix It Up - February 2008
Mike Smalley asks: I bought a 2001 Kawasaki KX250 with about 10 hours on a rebuilt motor. On my first ride, as I was going along in first gear the engine bogged, shut off and wouldn't start again until I changed the sparkplug. I also noticed oil coming out of the exhaust onto the frame and tyre. The previous owner was running a 50:1 fuel/oil mixture when the book calls for a 32:1. Could that be the problem?
Dr Ross answers:Mike, two-strokes will always have a bit of oil around the exhaust and possibly leaking from the cylinder and silencer joints, too. It is nothing to be worried about. With the poor quality of pump fuel at the moment, fouled plugs are a common occurrence. The ratio you mix the oil at is different for each of the oil brands out there, and it's best to stick with what the oil company recommends. If the fouling continues regularly, you may need to lean off the jetting.
Kicks Like a Mule - February 2008
Peter Barnes asks: Since I've had my '96 YZ250 fully rebuilt and run-in, it's hard to start hot or cold, and it backfires and kicks back on me. It has the original carby on it with a 40 pilot and 175 mainjet, and the jet needle clip in the top setting. The float level has been set and I am running an NGK8 plug. Hope you can help.
Dr Ross answers:Peter, the jetting sounds fine for your YZ, but you might want to check out the condition of your reed petals to see if there are any cracks or chips. This could affect the starting. If it was running fine before the rebuild, you might find the increased compression to be a factor in the hard starting.
Orange County Jail - February 2008
Pudds asks: I have an '06 KTM 250SX-F and the engine has locked up. I check the oil and have the bike serviced regularly, with new rings 40 hours ago and its valve clearance has been checked. It has an FMF Powercore muffler on it with standard jetting. Any suggestions on what to do would be great. Can you also tell me if anyone does a larger piston for them?
Dr Ross answers:Pudds, you say you fitted a new set of rings 40 hours ago? 40 to 50 hours is a long time to run a piston in one of these racing four-strokes. If you are riding the bike hard, pushing it to that many hours is very risky. I'm afraid you will have to have the motor stripped down to find the problem before I can offer you much additional advice.
E-Start Blues - February 2008
Matt asks: I have just picked up my '02 KTM 400EXC from being serviced a week ago and now she won't fire up on the electric leg. Instead, she just makes a ticking noise from the starter relay under the seat. The noise gradually fades away as I hold the magic button on. The blinkers and horn work fine while the engine is not running, and she fires up first or second kick the old fashioned way. I whacked her on the charger but the indicator says it's fully charged. Do you think the battery is dead or is it something worse, such as the starter motor?
Dr Ross answers:Matt, you should pop into your local auto electrician and get them to load test your battery, as it's quite common for them to show a full charge and still not be up to the task of starting the engine. Many bikes a few years old, like yours, are fitted with aftermarket batteries that have lower amperage than the original specification, and in cold weather, or after a few months, they just can't cut it. If the battery checks out okay, it might pay to check the exhaust valve clearance, as having them set too wide can stop the auto-decomp from working properly.
Dropped Skirt - January 2008
Peter asks: I recently took my 2002 KX125 to my local Kawi dealer for a new gear-shaft and some gaskets. When I got it back I rode it for only two hours before it dropped the piston and shattered the piston skirt. It was fully rebuilt about six months ago and I was wondering if the mechanic had anything to do with the shattered piston? He's telling me it was caused from not replacing the piston and rings often enough. What do you think?
Dr Ross answers:Peter, your mechanic is right; the most likely reason the piston would have broken the skirt off is from excessive clearance due to wear. A 125cc two-stroke race bike like yours needs a new piston about every 20-30 hours for the average rider. After six months you've probably ridden the bike for a lot longer than that. I recommend you fit an hour meter and inspect the condition of the piston and rings regularly.
Noise Works - January 2008
Thomas asks: With the MA reducing competition noise limits to 96dB in 2008, what exhaust systems or mods would you recommend to get some extra ponies from a 2007 RM-Z250 without making it illegal?
Dr Ross answers:Thomas, the noise limit has been this low in Europe for some time and any of the European pipe brands should be a safe bet for a performance boost while still being under the limit. I have been using the Akrapovic systems for several years now, both at team Kawi and here at KTM, and recommend them highly.
Sick CRF - January 2008
Visser asks: We've purchased an '06 CRF250X new. It's stock except for a Pro Circuit 496 pipe. The bike runs pretty good but it's got a flat-spot off idle where it coughs and tries to cut out. We've taken it back to the dealer who played with the mixture screw but it still has this coughing problem off idle. My dad and I think it's probably something to do with the needle clip or mainjet size. What do you think?
Dr Ross answers:Visser, most off-idle cough problems relate to the air/fuel ratio being too lean although, just about any bike can bog if you turn the throttle fast enough. You should adjust the air/fuel screw on the bottom of the fuel bowl, winding out the adjuster to richen up the mixture. This screw should be at 1.5 to 2 turns out. If you have the best throttle response at more that 2.5 turns out you should fit a larger pilot jet and start again with the screw set at 1.5 turns out. You can also get better response by adjusting the pump. There is a small screw on the right-hand side of the carby under the black plastic cover that changes how much the accelerator pump is depressed. By the process of trial and error, you should be able to eliminate your bogging problem.
Push Bike - January 2008
Aaron asks: I bought a new '07 KTM 450SX-F which I've been having starting issues with. My first ride lasted about 30 minutes followed by a two-and-a-half-hour push back to the ute. The bike was back in the shop the very next day, but the service manager told me they couldn't find anything wrong with it. Since then I've had about five hours actual ride time and about four hours pushing time. I charge the battery fully before every ride and the bike will start fine but will then die with no warning and the battery will be dead. Can you help me with any ideas for finding and fixing the problem, or is there a small portable battery jumper system that I can carry in my Camelbak. Any advice would be greatly appreciated.
Dr Ross answers:Aaron, your KTM is most likely running too lean on the pilot jet, which would make it harder to hot-start and also cause you to excessively crank the engine, which would be why your battery is going flat. We fitted a larger pilot jet and have been able to run all the Motorex KTM team bikes with the small battery all year, even in winter. On extremely cold mornings it could be worth having a jumper pack on hand and you can buy these for about $70 at discount stores like Supercheap Auto. As to why the battery would go flat while the bike is being ridden, it could only be either a faulty battery or a problem in the charging circuit. Your dealer should be able to diagnose both of those if that was the case.
Vertically Challenged - January 2008
Matty asks: I have a 2000-model WR400F and I have trouble touching the ground with both feet. I've heard of rear linkages that can bring the seat height down but have been unsuccessful trying to track one down so far. Any advice or information about suppliers would be greatly appreciated.
Dr Ross answers:Matty, the best and safest way to lower your WR400F is to have a competent suspension tuner lower both the fork and shock to suit your height. I know several shorter riders and female racers who have lowered their machines by as much as 30-40mm. Most of them simply can't believe how much better and more confidence-inspiring the bike is to ride when you can touch the ground. The mod isn’t cheap but the pay off will be worth it. Race Tech dealer Shock Treatment charges around $400 to lower both ends.
Long Haul - December 2007
Ian Simpson asks: Next year, two mates and I are planning a trip from central NSW to Uluru and back. We ride a 2004 WR450F and a 2006 CRF450X. I am looking for advice on how to best set up the bikes so we actually make it or can you suggest someone I can talk to? Any info would be great.
Dr Ross answers:Ian, if the bikes are in good shape they both will make the trip. Just keep up the oil changes and look after the air filters. I suggest you get damped rear hubs fitted to each of the bikes if you're going to be on the highway for any great distance. Also, fit a long-range tank to both bikes. The secret to making these type of trips is planning. Make sure you have the gear for the trip organised in advance, particularly oils and spares. Knowing how far apart the fuel stops are and how far your bike will run on a tank of fuel is essential. Every day should be totally planned so you don't find anything out the hard way! Gary Williams from Wombat Motorcycles out at Windsor, NSW, has prepped plenty of WR-Fs for rides like this, so give him a call. Good luck out there!
Power Hungry - December 2007
Webby asks: I own a 2007 KLX250 and the problem I have is it's run out of power for me. I've been looking at the 300cc big-bore kit which I'm sure will increase the power output, but as I was browsing the net I found a 330cc kit in America made by Kustom Kraft which is basically the same deal: new barrel, piston, rings, etc. Now I am in two minds on which one to get.
Dr Ross answers:Webby, converting the 250cc to 300cc is a snap and totally reliable. The 330cc kit could be pushing it too far. Give the guys up at Newcastle Kawasaki a call. They are the Ballard's of the green team and have all the good mods worked out for the KLXes. You can also check out ADB's story on the 300cc kit in the September issue.
Slippery Ground - December 2007
John asks: I am a proud owner of 2007 CRF250R. I have a couple of bottles of Motul Transoil Expert two-stroke 10W-40 gearbox oil at home from my previous motocross bike. Can this gearbox oil be used in my four-stroke gearbox and, if so, will it do any damage to my gearbox?
Dr Ross answers:John, your CRF250R is one of the few bikes on the market that separate the gear and motor oils, so you can run the two-stroke gear oils in the CRF's gearbox.
Fluid Retention - December 2007
Peter asks: I've noticed on the WR450 Project bike in September's ADB mag, that the coolant overflow bottle has been removed. I have an '04 WR250F that I'm trying to trim some weight from. Can I remove this bottle on my bike also? Will this have any effect on the cooling system? Do I re-route the coolant hoses to the bottle anywhere else or do I block them off somewhere? Are there any dangers in removing this bottle?
Dr Ross answers:Peter, you can remove the bottle and re-route the hose down the front frame tube to the bottom of the frame near the front engine mounts, with the help of a few zip-ties. This is how it is on the YZ-F models and the only drawback is that the expelled coolant is lost and there will be a need to check the level more regularly. If you regularly overheat the bike it might be best to leave it on.
Shafted - December 2007
Mike asks: I have recently purchased an '06 KX450F with about five hours on it. While practicing I noticed that my bike was making weird noises, and found that my front sprocket appears to have worked its way nearly off the shaft, causing most of the tranny oil to leak. The shaft appears to have quite a bit of play, perhaps more than normal. I fear I may have to replace the shaft seal and/or bearings that hold the sprocket shaft in place. It also seems that the nut that holds the sprocket on has stripped or worked itself onto the shaft. Is the shaft thread normal (clockwise) to tighten? Please help!
Dr Ross answers:Mike, the thread is normal direction-wise. The nut should have been thread locked from new and the Loctite used for this is pretty strong, which could explain the tightness on the shaft now. If the shaft is damaged, you're going to be in for a big repair bill to strip the motor down and split the cases to replace the shaft, so hopefully it isn't. The tightening torque is quite high on this nut and most issues with that particular item on the KX450F relate to not being able to get them off! I have seen a few that refused to come off easily. You should get the nut off and inspect the shaft for damage. If the shaft is okay, replace the O-ring that sits behind the collar. Also, check the sprocket for damage and replace if necessary, re-fit the nut (use a new one if there is any sign of damage) and tighten to 93ft/lbs with fresh Loctite and all should be good. Don't forget to check your oil level, too.
Neutral Position - December 2007
Stuart Day asks: I own a 1989 Yamaha DT175 but there's a problem with the gear selector on it. When I am out riding, it gets stuck revving between gears before jumping into the next gear. What do you think is the problem and how much will it cost to fix?
Dr Ross answers:Stuart, your 18-year-old DT most likely has some worn out gears. To have the motor removed and cases split to diagnose and repair the problem is going to cost you at least $400 plus parts. I would be putting aside $600 to $800 for the whole job.
New Threads - December 2007
Shawn asks: I've got a Suzuki DR250 1982 model. My wife calls it the POS (piece of shit), but I love it all the same. My problem is: I went to change the oil and stripped the thread on the sump plug. The bike isn't worth getting a mechanic to look at it as it only cost me $200. Do I use a tap and die set to re-thread a new hole, and will this leave metal shavings in the motor?
If so how would I flush these out?
Dr Ross answers:Shawn, you can ether tap out the thread to a bigger size or fit a heli-coil. Make sure you put a bunch of grease on the tap when you cut the thread to catch the swarf, and be careful to flush the hole with some motor oil before you finish, and you should be okay.
Untapped Potential - December 2007
Alan Smithies, asks: I have a DR-Z400 and purchased an IMS 14-litre tank. The first time I filled the tank I thought something was strange when it took 20 litres. It seems that 14 litres can be used and the other four litres just sit in the wings of the tank, which sit lower than the fuel tap. Any bright ideas?
Dr Ross answers:Alan, short of fitting additional fuel taps, lines and a vacuum pump, the only other thing to do is start wheeling!
Worrisome Whine - November 2007
Linton Towell asks: I own a '05 Honda CRF250R. For some time, it’s had a whine coming from the engine. It's not very loud, until you engage the clutch and put the motor under load. I was wondering if it may be a cam bearing, or clutch and idler gear bearings? Everything looks fine and the bike’s oil is replaced regularly.
Dr Ross answers:Linton, I can't think of any single part that could be making that type of noise under load. The only answer would be to strip down the motor and inspect all the spinning gears, surfaces and bearings. It could be hard to track down any other way if the noise isn’t getting any worse and there is no metal showing up in the oil or filter. And congratulations, Linton, your letter has earned you a Shell Oils prize pack valued at $150 from the boys at Moto National.
Pipe Dream - November 2007
Dave Smith asks: I'm in the process of screwing together a deal to purchase a '08 Yamaha WR450F. The factory exhaust system is okay but I want more power without it being too loud. Will the exhaust system off a '08 YZ450F fit the WR? I like the idea of a 'punched cone'. I ride on private property so noise isn’t too much of a problem for me.
Dr Ross answers:Dave, the YZ-F muffler is going to liven up the WR-F quite a bit. The newest YZ-F muffler seems to be very effective at controlling the noise without power loss. If you can talk the dealer into fitting it for free go for it. As for fitting, I haven’t seen both bikes in the same place at the same time so I don’t know for sure if they’re interchangeable, but all of the earlier ones have been.
Bottoms Up - November 2007
DJ Funky asks: I ride a '04 Honda CR125 and was wondering how often I should rebuild the bottom-end? What parts are involved and is the job very difficult?
Dr Ross answers:Funky, generally the cranks on 125s should be replaced every 50 hours or once a year. Lots of people get a couple of years out of them, but running them until they fail is the wrong way to go about it. If you’re racing the bike, it's cheap insurance to rebuild it each season. As for doing the job yourself, the Honda owners manual is perfect and will guide you though the job. But you’ll need a few special tools – such as heat and rattle gun – to get it done properly. If you’re going to tackle the job you’ll need to replace the crank, main bearing, main seals and gaskets.
Red Hot Ride - November 2007
Steve Dalton asks: I've bought a brand new '06 Honda CRF250X and am looking to make it snappier without losing too much top-end. I was thinking a hot cam and the White Brothers XCR pipe. I've opened up the airbox like the CRF-X mods, so what jetting do you recommend? Any advice would be appreciated.
Dr Ross answers:Steven, most of the guys have been running a 175 mainjet, 42 pilot jet and 55 leak jet with the fuel screw set at two turns out with an open pipe fitted. This should get you close. The White Brothers pipe will liven things up and the cam will get the CRF-X up to a reasonable speed.
Slippery Ground - November 2007
Nathan Euston asks: Hi my name is Nathan and I'm 12 years old. Could you please tell me which is the best gear oil to use in my Honda CR85? Mum bought Silkolene two-stroke gear oil. She says it’ll be fine, but mum doesn't know much about motorbikes. Also, my manual says to change the fork oil after seven hours but a few people said it’ll be fine to leave it. What should we do?
Dr Ross answers:Nathan, I'm sure your Mum's a smart lady. I learnt a lot about bikes from my Mum, growing up in a single parent family. Silkolene Pro Gear is one of the best two-stroke gear oils on the market. Be sure to change it often. As for the fork oil, seven hours sounds a bit too frequent for a casual rider and most owners simply service the forks every six months.
Cranky Kato - November 2007
Billy Denton asks: My '06 KTM 625SXC has two problems. When revving the bike hard before returning to idle, it'll stop. But if you keep blapping the throttle for 20 seconds, it'll then idle. It was fitted with an Akrapovic muffler and a 190 mainjet from new by the dealer, even though KTM recommends a 188 main.The second problem is the clutch. It started to be noisy at 45 hours or about 2500km until I pull the clutch lever in. The dealer tells me this is a KTM trait. As the bike is still under warranty, any information would be welcome. Last thing: do you know where I could get a steering damper for the 625?
Dr Ross answers:Billy, the clutch noise is a known thing on the older LC4 motors. The baskets are a hardened alloy and they ring like a bell at idle with the clutch plates rocking back and forth. When you spread the plates by pulling in the lever they don't all move together and make less noise. The jetting could still be a bit lean on the pilot jet, or your idle could be set too low. It's pretty common to see the idle too low on these motors as they will happily bump away at 500rpm when the idle is supposed to be at 800-1000rpm. If you hear the auto decomp clicking occasionally, your idle is too low. As for the steering damper, either the Öhlins, Scott or MSC damper from Shock Treatment (02 4773 9115) are the best. You can’t beat them.
E-Start Blues - November 2007
Ian Lewis asks: From new, my '05 Berg FE650e had power to burn, but developed flat battery symptoms at 115 hours (due to the juice required to turn her over). I run it slightly rich from some needle jet and pipe mods. I've checked timing, valve clearance, multi-meter, given it new batteries and contacts and overhauled the starter motor, and all appears fine. The web shows a picture of an auto decomp mod with a weld on the back of the counter-weight to make it activate better. There’s only slight wear on mine and the bearings check out okay. I can see it activating prior to TDC but there’s still bulk compression. The mod looks like it would work – what do you think?
Dr Ross answers:Ian, there's a good chance that the auto decomp activator is worn and not depressing the valve far enough or for long enough. David Woodard, the technical guru for the Husaberg empire, suggests that you should test for wear in the decomp by closing up the exhaust valve clearance to the minimum setting to see if that improves starting. If it does you’d be safe to go ahead and order a new decomp assembly. If not, you’d better have the wiring, battery and starter system tested for voltage
drop while starting.
Legal Advice - October 2007
Matt Foster asks: I've just got my motorbike Learners licence and want to get a newer bike that's registrable. I'm still very unsure of what to get as I'll be using it for rides of about an hour on the highway but mostly for off-road trails and the occasional jumping session at the motocross track. I've got either the WR250F or a Husky TE250 in mind. Which bike would be best suited to this sort of riding?
Dr Ross answers:Matt, both the WR250F and TE250 are great off-road racing bikes, but they're not really built for hours of highway riding. With off-road gearing, the life of the engine will be used up very quickly. If highway use is going to be minimal, the Yamaha motor is a proven thing and that's where my money would go.
Decomp Query - October 2007
Anthony asks: I own an '02 Yamaha YZ250F which I'd like to upgrade to auto decompression. I've heard that it's just a matter of installing an '03-onwards cam and timing sprocket. Is this correct? Or are there other mods that will need to be done?
Dr Ross answers:Anthony, many early WR-F owners have updated to the '03 exhaust camshaft to get the easy starting of the later model. I have fitted these many times. Just order the cam from the '03 model, which comes with the cam wheel already on it and is ready to fit. Then just follow the steps in the owners manual and you'll be fine.
Idle Chit Chat - October 2007
Nathan Matthews asks: I've always had four-strokes, but have just bought a '96 KX125 at a good price to use as an extra bike so a mate can come with me. It has just been rebuilt, and has most of the racing mods including a Pro Circuit pipe and aftermarket reeds. The thing is actually quicker than I thought it would be. My problem is jetting; the bike won’t idle at all. Have you got any tips? What mixture ratio would be best? And is too much oil in the fuel going to do damage? I found out that the previous rider had been using a 25:1 mixture.
Dr Ross answers:Nathan, basically the KX125 isn’t meant to idle. It is a motocross bike after all and, as such, it has been designed to be started, revved up and raced away from the startline. Sitting there and idling away while you open and close a gate was never in the design brief for the little KX. Given that the KX is now 11 years old, I can imagine that the carby would have some wear in the needle and slide, making holding an even idle less likely. If, after adjusting the idle screw, the bike seems to hold the right revs for about 10-15 seconds before stalling, that would be pretty normal. Getting it to purr like a four-stroke just isn't going to happen.
Arm Pump - October 2007
Nathan Jones asks: I've bought an '07 KX250F which I have only ridden a few times, but when I do I can only ride it for a short period of time due to major arm pump. I weigh about 65kg and I want to be able to ride a five-lap race without too much trouble. How do you think I can overcome this? Do you think suspension set-up is the key to this problem, if so, can you suggest a way to alter my suspension?
Dr Ross answers:Arm pump is a serious issue for a lot of riders, Nathan, but unfortunately you haven't mentioned much about yourself, your age, abilities, how often you go riding, or about your off-bike training schedule. Many Pro riders suffer from this and often the cause isn't bike-related. At 65kg you are a little lighter than the average rider, and depending on your ability you could benefit from slightly softer springs. The non-bike related theories are vast and varied. Mostly, the problem is that the rider hangs on too tightly to the bars and overworks the forearm muscles, causing them to "pump" up and block blood flow to the hands. Riding more often and becoming more relaxed when racing are the most effective solutions.
Spending My Change - October 2007
David asks: I recently cracked the engine cases on my Yamaha WR400F (long story), but since then, we've rebuilt the motor and have some spare change. I'm after a billet clutch cover, but GYTR don’t make 'em for my model and I don’t know any other brands that fit. Can I fit a clutch cover off a WR/YZ450F, as they seem very similar in shape?
Dr Ross answers:David, SFB racing has covers listed for your YZ400F. Give Steve at Cisco's in Melbourne a call on (03) 9801 9022. The SFB Part number is 2400420201
Weird-Ratio Transmission - October 2007
Andrew Leonard asks: I've just bought a '92 Yamaha WR500. I was under the impression that WR meant "wide-ratio transmission", hence the reason I bought it over a CR or KX500, but it has the same ratios as the YZ490. I use it for open riding and have geared it to 15/44, but top gear is still too low. I can't gear it much higher as the chain is getting close to the case and the rear hub. Also, at this gearing, the jump between first and second gears makes technical stuff and hillclimbs from a standstill really difficult. With all your experience and connections you may know where I can source an aftermarket wide-ratio transmission.
Dr Ross answers:Andrew, it's a very brave man who needs more from a WR500! The gearing you have is good for up to and over 140km/h. You either need a KTM 950 Super Enduro or to start looking for more challenging terrain!
Swingarm Swap - September 2007
Chris Carey asks: I own a 2007 KTM 250EXC-F. My swingarm has been badly damaged in a crash over some rocks, and I want to replace it with a swingarm from an '07 SX. I noticed Ryan Marmont had a new swingarm fitted to his '06 SX race bike last year, which shares the same frame as my bike. Will the swingarm fit, or are there big modifications involved? Thanks.
Dr Ross answers:The swingarm will fit, Chris, but you will need to heat up the airbox to make more room for the shock reservoir as the swingarm mount is further back and will pull the shock into the plastic. Also the shock needs to be shortened 6mm, revalved and a softer spring fitted to match the more aggressive rising rate. Other than that, it goes straight on. And congratulations, Chris, your letter has earnt you a full set of SBS brake pads and a hat and tee worth $150 from our mates at Monza Imports
Get Up & Boogie - September 2007
Michael asks: I own a 2003 Honda CR125 and would like to know if these aftermarket expansion chambers and mufflers really work? I wouldn't mind giving my bike a bit more get-up-and-boogie attitude, but I don't want to spend $1000 on something that's only going to make my bike louder.
Dr Ross answers:Michael, I tested all the pipes for the '03 CR125 while helping out supermoto star Nick Brain, back when he was a struggling privateer motocrosser. The best combo was the FMF Fatty and Power-Core muffler. If you have the budget, get yourself a VHM head and V-Force reed-block. Those three items will really wake up the CR!
Stoppp! - September 2007
Ian Campbell asks: I just bought a Kawasaki KLX250 and the front brakes are woeful. Even from new, I could pull the lever almost to the handlebars. I've tried the usual tricks of removing the glazing off the pads and bleeding the system, but it hasn't helped. Any ideas on what I could do?
Dr Ross answers:Ian, yes the KLX is fitted with possibly the spongiest front brake on the market. Luckily all it needs is a new braided front brakeline. I fitted a Goodridge line from www.johnstamnas.com on a project bike a couple of years ago and it did the trick. They're Aussie-made and one of the only ADR-approved aftermarket brakelines on the market.
Water Worries - September 2007
Justin Sellings asks: I have a 2001 Yamaha YZ426F that loses water (approx. 300ml) out of the radiator every ride. I'm not sure if this is common, but the bike was rebuilt approx 30 hours ago and is serviced every 10 hours I recently bought new coolant and a new radiator cap and I've checked the oil, and there's no water going there. It just seems to be coming out of the overflow. Any ideas?
Dr Ross answers:Justin, it could be that the head gasket isn't sealing and the compression gasses are forcing out the water. 300ml is way too much to be losing and you need to get to the source of the problem before the engine winds up damaged.
Poor Bastard - September 2007
Ryan Henry asks: I own a 2004 Honda CRF450R, and it "detonated" when an acquaintance took it for a ride. From what I gather, he rode it like his two-stroke waiting for the power-valve to kick in. The result is that everything from the cam and valves to the bottom-end is destroyed. Do you know anywhere I could purchase a replacement engine?
Dr Ross answers:Ryan, Honda doesn't offer complete replacement engines for your CRF.
Although, with plenty of people in the same boat as you with three- or four-year-old bikes with blown motors, you'd think they would! The way it's done is: simply make a huge list of the damaged items and weigh up the cost against the replacement cost of the bike... sorry!
Grim Rooster - September 2007
Tony asks: My nephew has a Yamaha YZ426F he bought last year that developed a death rattle after a ride in the dunes. Apart from being hard to start now, it otherwise runs okay. We checked the timing chain adjuster according to the manual but it still vibrates. Are we looking at major surgery or a simple valve adjustment?
Dr Ross answers:Tony, unfortunately the 426's rattle is unlikely to be due to valve adjustment. Riding in the dunes is very hard on any bike and it could be he has overheated the top-end and had the piston nip up. I would recommend you put a new piston kit in and check the big-end and main bearings while the top-end is off. His 426 is a few years old now and it's probably overdue.
Clutching At Straws - September 2007
Ryan Warnes asks: I own a 2002 Gas Gas EC200 with a hydraulic clutch. When riding, there is no sign of clutch wear or slippage. However, with the clutch pulled in and a cold engine, it stalls when put into gear. Yet after a slow lap when the engine's warmed up the problem goes away. Does it need adjusting somewhere? Am I not changing the oil regularly enough? Or do I need a new clutch?
Dr Ross answers:Ryan, the plates in your clutch are simply sticking together. It could be because the oil is too thick and they don't separate until the oil is heated up and thinned out. Try changing the oil to auto transmission fluid (Dextron III) or a quality two-stroke gear oil and see if the problem goes away. You should change the oil in your two-stroke gearbox after every 300-500km of off-road riding.
Bitter Pill - September 2007
Will asks: I recently had an accident resulting in a knee reconstruction. The doctors told me I'll never be able to kick-start my '99 Honda XR250 again. It's a pretty bitter pill to swallow, so I'm wondering if I can install an electric start on my XR, and how much would it cost?
Dr Ross answers:Will, fitting a electric start to you XR is way too expensive to even consider. You'd need to replace both cases, the crank, as well as buy the starter, switches, wiring and a battery. There are great e-start alternatives like the 250EXC-F and WR250F out there to get you back on the trails!
Hard & Fast? - September 2007
Robbie Bateman asks: I just rebuilt my Yamaha YZ250F, and I’m after a bit of advice on how to run-in a ebuilt engine. I’ve heard the best way is to go hard and fast, but is this true?
Dr Ross answers:With most of the newer 250Fs, there is little or no running in to be done. If everything is assembled right, things will be fine. Taking it easy for a few laps to check for oil or water leaks is all that passes for running in nowadays!
Service Me, Please - August 2007
Kirk Lancaster asks: I own a 2006 KTM 250SX-F, and would like to know a bit about servicing the bike. Firstly, can I do the valve clearance test myself with limited knowledge? The bike's done about 40 hours since I bought it. Also, when should I look at getting a top-end rebuild done?
Dr Ross answers:Kirk, checking the valve clearance is very straightforward and most owners should be able to check the clearance. If an adjustment is required, I think a dealer should probably do the work as you need to remove the cams to get to the shims. After 40 hours, the little SX-F is overdue for a clearance check. If the bike is ridden hard, the piston rings are probably due for replacement, at the least. I would recommend a top-end rebuild every 30 hours if you're racing and revving the bike hard. And congratulations, Kirk, your letter has earnt you a full set of SBS brake pads, a hat, and a tee – a pack worth a total of $150 from the crew at Monza Imports.
Top-End Issues - August 2007
Shane asks: My son has just rebuilt the top-end of his 1998 RMX250, but it now has no power up top. He dropped the main jet from 170 to 169 and raised the needle clip to the middle, but it's made little difference. Bottom-end power is fine. Any ideas?
Dr Ross answers:Shane, your boy has managed to re-fit the cylinder without the power-valve hooked up correctly. Have him remove the pipe and power-valve cover and check the arm is hooked up correctly. Chances are it isn't!
K&N Query - August 2007
Ryan asks: I was reading ADB and came across an ad for K&N air filters. I own a 2004 CRF450R, and want to know what you can tell me about them? As you know, the CRF's valves are screwed if even the smallest bit of dust gets in. Do the K&N filters effectively seal the airboot? Are they like the genuine Honda filters that don't have a very large surface area?
Dr Ross answers:Ryan, I haven't had much experience with the K&N product, but have used the excellent DNA filters in some dirt bikes. Both DNA and K&N use oiled cotton, rather than foam or paper. Believe it or not, the paper-type filters actually have more surface area than some foam filters. The paper elements also filter the air more efficiently than foam, trapping finer particles. They work well ... but for pure off-road, there are drawbacks: the maintenance, cleaning, and the overall life of the paper doesn't add up for me.
Dr-Z Advice - August 2007
Stuart asks: I own a 2000 Suzuki DR-Z400E and love it, but I'm looking at buying a new speedo. What do you know about the Trail Tech speedos? Also, to add power, would you recommend the PowerNow as money well-spent?
Dr Ross answers:Stuart, the Trail Tech product is the pick of the litter in aftermarket speedos. It's feature-packed and the units survive the off-road bumps and scrapes quite well. The PowerNow is great for improving the bottom-end throttle response on most bikes. If you've already fitted an aftermarket muffler and rejetted it, this would be another step forward.
Oily Issue - August 2007
Koen Voorhuis asks: I own a 2004 Honda XR650L, and I need some advice as to which motor oil would be best. Since I live in Burkina Faso and it is very hot and dusty here, I change the oil every 3000km. Is a synthetic oil better? Also, can I put synthetic motor oil in the fork of my bike?
Dr Ross answers:Koen, yes, a full synthetic oil will help protect your XR's motor better in a hot environment. I always recommend that everyone should use the best oil they can afford, and change it often. I've been using Motorex's new Power Synt 4T oil for a while with outstanding results. It's a 10W-50 oil that works well in the heat, and still offers good wear protection without causing the clutch to slip. As for your fork, use fork oil. Most of the better brands are synthetic, or at least synthetically modified.
Poor Design Or Unlucky Hit - August 2007
Greg Kay asks: I recently bought a 2004 Yamaha WR250F, and am just getting back into trailriding after a 12-year lapse. A few weekends ago, I came off while attempting to cut across the face of a rocky hill-section. The right-hand footpeg hit the uphill and threw me down the hill. I continued home and noticed oil dripping from the left-hand crankcase cover – the gear lever pushed a hole through it! If I'd kept riding, the bike would've run out of oil and seized. A new cover from Ballard's Offroad cost me $170, but I'm wondering if this is a design flaw with the WR-F, as the metal cases seem very thin. Is there a way of reducing the risk of this happening again – without making sure I never crash in the future?
Dr Ross answers:Greg, when you throw a motorcycle down a hill, things will break! Broken cases caused by the gear lever is a rare occurrence. The only real insurance is a good bashplate. Whipp's has an excellent bashplate that wraps around
Eighties Conversion - August 2007
John Laidsaar asks: I'm restoring a 1981 Honda XL500S and want to convert it to 12 volts. What components will be required?
Dr Ross answers:John, I think the process should be easy. The stator needs to be re-wound, and you'll need to replace the regulator, fuses and bulbs. Give the guys at Small Coil Rewinds in Geelong a call on (03) 5218 8454.
Plugged Out - August 2007
A. Hibbins asks: I have a problem with a 1997 Honda XR100. After starting and idling for a couple of minutes, it starts to idle rough and eventually stops. When I pull the plug out, it's sooted-up with black carbon. Change the plug for a new one, and it's the same scenario. There's no smoke blowing out the exhaust. Can you help?
Dr Ross answers:Your XR should idle away for hours and run perfectly. My guess is that the choke could be stuck open and the overly rich mixture is the culprit. With the bike's 10th birthday just round the corner, it could be time to treat her to a proper service at a dealer. Have the carby stripped and cleaned, and the valves adjusted as well. The little XR will soon be purring away happily again.
EXC-F Front-End Blues - July 2007
Mike Ryan asks: I recently bought a 2007 KTM 250EXC-F, and it's an amazing bike to ride. I found it has awesome tractability, and just keeps on delivering right through the rev range. The only mods are the standard KTM gear such as handguards, bashplate and case-guards. My problem is that the front-end may as well be welded solid. I read the articles recently in ADB on the shootout and this was an issue raised. Have there been any solutions? Can we revalve to the specs of the earlier fork, or is lighter oil an option?
Dr Ross answers:Mike, the fork seems to just be over-damped. Just about any good suspension tuner should be able to sort it out. I would give Terry Hay at Shock Treatment a call; that's where KTM factory off-roaders Brad Williscroft and Ben Kearney get their suspension sorted out. And congratulations Mike, you've scored yourself a pack of Shell Oils worth $150 from our mates at Moto National.
Choking Up - July 2007
Geoff Baines, asks: I have a 2003 Yamaha YZ450F and it won't run unless the choke is on. I just installed an aftermarket fuel screw on the bottom of the float bowl. Everything in the carb is set to factory specs (fuel screw two turns out, main is 165, idle is 42), but it won't idle unless the choke is pulled out, and occasionally fuel will spill out of the bowl drain tube. There are no air leaks around the boot of the carb, and everything looks normal. What have I missed
Dr Ross answers:Geoff, it sounds like you may have installed your slide incorrectly. When installed properly, you will see a small hole near the bottom when you look from the engine side. It might also pay to remove the pilot jet, hold it to the light and confirm that you can see a clear round sharp edged hole ... if the hole appears blurry or soft, it will not work, and it'll need replacing.
Good luck!
Swapping Heads - July 2007
Dave Illot asks: Hey Doc, I have a quick question – is it possible to swap the head from a 2004 CRF450R to the 2006 CRF450X? If not, how come?
Dr Ross answers:Dave, from what I know of the CRFs, the heads will be interchangeable, as are a number of other parts around the bike.
Leaky Ship - July 2007
Glen Atkinson asks: I own a Honda XR600 that recently started to leak loads of fuel from the overflow, so I had the needle and seat replaced, fitted a fuel filter and made several adjustments to the float level. However, it still leaks fuel occasionally. What else should I do to try and fix this?
Dr Ross answers:Glenn, you’ve pretty much covered the usual fixes for the leaking needle and seat causing fuel to overflow. At a guess, the occasional leak you are now experiencing could be from the float level being too high, or a worn carby could be causing things to stick a little. If it’s a big drama, you might have to install a new carburetor.
RMX Flat-Spot - July 2007
Steve asks: I ride a 1997 Suzuki RMX250 that I bought a while back. The bottom-end and mid-range power is great, but it has a massive flat-spot when you try to rev it out into the top-end. It feels fluttery, like there's no powerband. Is it starved of fuel? The bike has a Pro Circuit pipe, and apparently it used to run great with the stock pipe, so the issue may be related to that.
I was thinking the main jet size needs to be increased to match the new pipe (the carby is still standard as far as I know), or maybe we need to look at the power-valve and make sure everything is as it should be. I gathered this info from the owners' manual: Keihin PJ38 carby, main jet #180, main air jet #200, slow jet #60.
Dr Ross answers:Steve, the RMX jetting is famous for problems that are caused by the ageing PJ carby. The PJ-series carby can be tuned by adjusting the bleed on the choke knob. This seemed to work fine when the bikes were new, but after a few years, the jetting issues seem to be incurable. The standard problem-solver is to buy a PWK38 or 39 carburettor and fit this with 42 pilot, 172 main and a DEL needle on the middle clip. With these mods, the bike's jetting troubles will be behind you. A mate of mine picked up one for his RMX for $200 on eBay recently. You can probably do the same, or buy one from any major wreckers. Good luck.
Lights & Action - July 2007
Bryce Lysaght asks: I own a 2001 Kawasaki KX250 two-stroke and have set it up for enduro this year, including a bashplate, handguards, and mods to the engine. All that I'm missing is a headlight and a tail-light. I've spoken to my local dealer and the guys at Ballard's, and my cheapest option is nearly $800. Is there another way to wire up a headlight on my bike? Perhaps take parts off a KDX200/250 or something?
Dr Ross answers:Lights on the KX shouldn't be a big issue, as long as using LED-style lamps to satisfy the off-road/enduro tech inspection is all you're looking for. GNCC racer Josh Strang's father Vince has used a basic kit on Josh's KX250s for the past couple of years, and they're available from Bert at Small Coil Rewinds in Geelong, Vic (03) 5278 8454. Basically, this kit "steals" a bit of power from the ignition circuit to run the LEDs. The Small Coils kit is just wires, LEDs and some instructions. You simply fit the LED bulbs into any aftermarket headlight or tail-light. Vince silicones them into place where the normal bulb goes. Aftermarket tail-lights are available, too, and you can wire one of those up if you're going to buy a tail-light assembly.
Slippers - June 2007
Jed Wallis asks: I own a 2005 Husaberg FE550e that I ride mostly on tight bush trails. I also have a set of motard wheels. I know the benefits a slipper clutch has on the tar, but what about the dirt? Is it true that a slipper clutch will reduce engine braking on a four-stroke motorcycle in a dirt application, reduce diving, and make the bike handle a little bit more like a two-stroke. A slipper clutch is a large investment, so it would be good to hear about their advantages.
Dr Ross answers:Jed, slippers will reduce supermoto lap times and are a proven thing in the sport. However, in motocross and supercross, they're still rare. Many Pro riders are rumoured to use them for SX where it’s better to have the bike's rear-end contacting the ground and the rear wheel turning as the throttle is snapped shut.
I have had some experience with the Hinson slipper clutch. They come with three springs that make the uptake of the slipper adjustable to suit all riding disciplines. On a big-bore like your 550, you'll easily notice a big difference. Whether or not they’re worth the money, only you will know once you have one.
Sitting on a Timebomb? - June 2007
Alan Chatfield asks: I own a 2003 Honda XR250R and every time I ride it, there's always a problem. When I hold it pinned, every now and then it just conks out and rolls. I can also hear a loud ticking noise from the front part of the engine. What do you think is the problem?
Dr Ross answers:Alan, the XR250 has a bullet-proof motor but a four- or five-year-old one could have some issues. If you're unsure of its service history, you should have the bike checked out at a Honda dealer. The ticking noise could be a sign of valve trouble that will be cheaper to fix earlier rather than later. The cutting out at full revs at speed will be fuel-starvation or an electrical problem.
Swapping Heads - May 2007
Dave Illot asks: Hey Doc, I have a quick question. Is it possible to swap the head from a 2004 CRF450R for one from a 2006 CRF450X?
Dr Ross answers:Dave, from what I know of the CRF's, the heads will be interchangeable.
Stopping and Starting - May 2007
Doug Simpson asks: I own a 2005 KTM 450EXC that tends to just stop sometimes for no apparent reason. The bike starts again after about a minute then runs fine. The dealer told me to blow out the stack of vent pipes coming from the carby, but this has made no difference. I have also changed the plug and drained the float bowl in case there was water in the fuel. Have you heard of this happening to anyone else?
Dr Ross answers:Doug, water in the fuel will do it every time. The water is much thicker that the fuel and will not pass through the jets in the carby. As the water blocks the jet, the motor is starved for fuel and stops running. Once the motor has stopped, the water will sometimes fall back down and clear the jet, then when you start the bike, the process starts again. Drain the carby and clean it out totally, including the accelerator pump assembly. While you're at it, drain the fuel tank and discard the contaminated stuff and re-fill it with fresh fuel.
If there is no water in the carby or fuel, check out the fuel cap vent – if it won't allow air into the tank to replace the fuel that goes out into the carby, a vacuum builds up and stops the flow of fuel to the carby. Once the bike sits for a few minutes or the cap is removed, the pressure equalises and the fuel will flow again. Hopefully it’s one of these two things; both are easy and cheap to fix.
Crunch! - May 2007
Ben Dewar asks: I'm 15 and currently ride a 2005 Yamaha YZ250F. Recently when practicing at my local track, I landed a jump and snapped my left footpeg – bracket and all – from the frame, leaving a big hole. Was it metal fatigue? What can I do to repair it?
Dr Ross answers:Ben, there are only two ways to fix it. Collect the broken pieces and have a competent welder re-attach them, or buy a new frame. The mount would've probably been cracked for a while and you just didn't notice it until the whole lot came off. If the mount has been re-welded in the past, the mount could have been weakened, or, more likely, was damaged in an earlier crash. In future, always keep an eye on the condition of the footpegs, pins, springs and mounts. Check them each time you wash the bike for damage and wear.
Water Prevention - May 2007
Jason McArthur asks: There's nothing worse than your bike spluttering and stopping in the first creek crossing of the day and then having to ride the rest of the day in wet boots! To pre-empt this scenario, our current approach is to temporarily re-route our carburettor breather hoses as high as possible so they're out of the water. I have recently re-routed these hoses up into the airbox, which I hope to leave there permanently. Is this okay? Are there any other permanent waterproofing strategies that could be made to bikes in general?
Dr Ross answers:Jason, if there's a lot of deep water around your riding areas routing the hoses and the engine breather pipes to keep them high and dry is a good thing. It will keep the water out, but remember the carb overflow tubes are meant to allow the spilt fuel to spill onto the ground and be replaced with clean air. As for other waterproofing tips; carefully applied duct tape can keep the water out the airbox, and dielectric grease and silicon on the wire connectors for the CDI and kill switch can save the day.
Riding Like a Pig - May 2007
Kirsty Somes asks: I recently bought a 2001 Honda CR125 that is fitted with a Pro Circuit expansion chamber and a standard muffler. The problem is when I take off, it always bogs and I have to continuously pull the clutch until the engine takes hold. I got the carby cleaned out and although it's better, the problem still exists. It makes it particularly hard riding the trails with technical hillclimbs. Any ideas?
Dr Ross answers:Kristy, the CR125 was never known for its bottom-end power. By 125cc MX standards at the time, the CR was weak. You should check the top-end. Make sure the piston, ring, and bore are in good shape. The rings on these old CRs do wear out quickly and a lack of bottom-end power is one of the first signs of a worn ring. Given that you have just bought the bike, you should have it pulled down and fit a new piston and ring. Also, many CR owners found that a 53-tooth rear sprocket worked well on that model.
Modern Bike Set Up - May 2007
Marty Pettifer asks: I've just bought a new Kawasaki KX250F but since my last bik