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Well it's time to rebuild my sumo, I have owned this bike for longer than any other bike I have had. I had cracked the frame and welded it the exhaust was cracking apart and the last straw was it sheared the flywheel off and sent rivets through the crank case. I had rebuilt this engine prior due to a broken rod so the engine is pretty fresh when this happened. I will share some old photos first then I will get to the build pics. this bike was raced in the 2003-2004 AMA supermoto series by Chris Caplinger, And I think it had seen a few other years of pro racing. by the time I got the bike it was pretty well stripped of it's original build goodies but it was still fast and handled well. But my aim was to find the old stuff they used and bring it back to a typical build of its time once the time was right. that time is now, she was tired!
the night i got it home around 2008 ish.





this is the cylinder when i broke the rod in three places, it was bad.

The crank and the big end of the rod broke

The piston and what's left of the rod


I raced it and track rode this bike since 2008 she was fast but clapped.



teardown begins!



out comes the engine.


Ill post more as I have time

hooray!

what a glorious bike!

Aaron Coomer (3.504) wrote: ↑Wed Aug 28, 2024 10:16 am hooray!

what a glorious bike!

Thanks Aaron, she"s about done as well

Awesome man!!

This should be a great build thread.

IIRC the first time we met, you were riding this at G&J.

ohioyj wrote: ↑Wed Aug 28, 2024 11:47 am This should be a great build thread.

IIRC the first time we met, you were riding this at G&J.

Most likely, has been my fav out of all that I have had.

A few engine shots, not going to go in-depth with the engine, but it has quite a few thing done here.






So due to the raced out condition of the frame I am replacing with the spare frame that it came with which is a 2004 frame, the 2003 2004 the swing are pivot holes different sizes 2003 is 15mm and 2004 is 17mm. the bearings in the swing arm and engine caes dictate that we retain the 15mm through bolt. this requires me to machine 1mm thick bushings for the frame which I show here I made most everything in house with my lathe or mill if needed.

Time for some dry assembly to fit the subframe and exhaust, the subframe requires the left spar to be longer about 15mm and the airbox requires extensive modification.



rebuild the front brakes, this caliper is old I think i may run this for a bit and switch over to a radial mount brembo or beringer radial. the existing brakes worked well but not much feel and kind of notchy.




Frame was sent off to powder the paint code is RAL2009. it turned out awesome. my powder guy is on point! the frame got the typical gusseting as well for supermoto.




I have got to get better at taking progress pics, as a pro tech it's the last thing on my mind.

She deserves it! Lookin good