So this all began when I decided to replace my cases due to them leaking. When I bought the bike the right side case was broken and crudely “repaired” above kickstart g [ Guests cannot view attachments ] ear. Since I owned the bike it got progressively worse so I got sick of it and wanted to bring the bike back to it’s former glory. The only time I went in the engine was to do a top end a few years ago when I was in highschool. I had la sleeve bore it to 68.25 with a wossner piston and I put a 22cc coolhead on it. Before I dissembled the bike I checked the compression which was 150 psi.

As far as the motor goes that kind of turned out to be a worst case scenario. Disassembled and intake side of piston/ cylinder had wear my k&n came loose and sucked dirt I believe. No more k&n for me! The crank was nice and tight but I wasn’t going in there multiple times so I figured rebuild that with new rod kit and new crank bearings. There was a lot of metal in the bottom end and after splitting the cases I found a burned up shift fork and gears with some wear. So I found some nice cases on eBay and a used tranny. I cleaned up all my parts and made one good trans out of the two.

So while the engine is away I ordered every bearing and bushing on the bike had my frame, a arms, etc powder coated by a local guy who did a good job and turnaround was only 5 days. I also ordered elka shocks through lonestar racing due to the fact I’m running their +2 + 1 a arms. I made very clear on the phone it was for a 91 and that 91-92 have a different rear shock and he said no problem. Well this was first week of may I didn’t hear a single word back until June. It was only suppose to be 2 weeks to build the shocks. Well they call back and say the front shocks are built but elka can’t make a rear shock they don’t have the parts to do so. So after all that time and they just tell me they can’t make the shock that I specially asked if they could make. Note this is not Elkas fault it is lonestar. I called elka direct which I should’ve done from the start they explain the fork on the bottom of the shock they don’t make anymore and the icing on the cake the fronts were never built. So lonestar said they will take 200 off the 1000 and I can have just the fronts or cancel the order.

Now it’s end of June and I got back everything from my motor except the cylinder which was being plated at powerseal in pa. I told them expedite it as I was going to my cabin in Maine for two weeks I wanted to ride. I got it maybe a week later. Now when I opened everything up I was not a happy camper. The head was not machined and I was under the impression it had to be cut to match the port. I also wanted the head stay machined off which wasn’t done. The crank was rebuilt with a hot rods rod I wanted pro x. Trans didn’t look like anything was done except clean up the slots where the dogs engage not backcut like how I wanted. I called rich and had him explain he said head didn’t need to be cut since running pump gas he forgot about machine work ( I left detailed note of what I wanted done) trans he said he undercut the gears and he said tranny should be good to go he was confident in it. I gave him the benefit of the doubt. Now I assembled entire bottom end and was waiting for the cylinder to come. Installed pro x crank bearings and seals, winderosa gasket kit with oil seals, ebc clutch kit, rebuilt waterpump new bearings impeller seals etc.

Well I also got the big volume pipe and silencer from dynoport that pipe looked great very happy about that. I assembled the whole bike now every bearing was replaced with all balls. Everything went together great minus the powder coat being thick causing a few minor issues but that was expected completely. I went with a new tm 38 carb using Zilla intake boots to a custom airbox and twin air foam filter. New carb the jetting was way off so I put in some starting point jets I believe 400 main 88+ zilla needle 35 pilot q8 needle jet. Got it running for a heat cycle sounded real good. But the damn clutch cover was leaking had no idea why cleaned everything torqued everything mating surfaces flat made no sense. So had to take apart my freshly painted engine to replace gasket. Overnighted one and found old gasket prefect. Installed new anyway still leaked... it was hours away from leaving for Maine now so last ditch effort I took apart cleaned everything and used the gasket with a little rtv where it was leaking at rear of engine below Kickstarter and put a little on outside of case.

Installed the last few finishing touches when I got home from Maine my frame guards and rear number plate retorqued motor mounts and cylinder they were all loose etc. still need to readjust camber it’s a little off. Set caster at 5* camber 4* and 1/4 toe in. Need to get better tie rods the oem style ends are junk two small or doing the bump steer mod made too much angle it looks like? Suspension works great just don’t like where my front rezzies are mounted. They were suppose to be piggyback rezzies that’s besides the point. Went on two rides so far since getting back and the bike feels great. Only complaints are shifting feels a little hard and hard to find neutral every once in a blue moon 1st gear won’t engage have to hold shifter down letting out of clutch. Also straight line drag race top end feels slow but could be porting I never use 5-6 but one of my buddies has a blaster 240 kit 38 mm carb running aviation gas few other mods honestly fastest blaster I’ve rode or seen but still a blaster lol. Also 400ex basically stock with pipe. They beat me in straight line race that seems odd losing that much top end but bottom end super responsive and I was hitting whoops 4th gear pinned blowing past them and felt faster than any bike I’ve ridden so I’m not sure what to think of it. Like I said bike runs great I believe the jetting is very close if not perfect. I need to get it on a track that will be the tell tale sign of how good it actually runs.

Stock main for an 88+ zilla was a 350.  87 was 420 but was a bit rich.

480 for that bike sounds pig rich!  No way you should be losing to a pipe 400ex in a drag race.

What does your spark plug look like?