HERE WE GO
To say Matt’s bike was used would have been an understatement. In no way was it abused or neglected, but it
was definitely visibly used and in need of some major
overhauling. The build started with tearing the bike down
to the frame and sending it off to Chris Johnson and his
crew at San Diego Powder & Protective Coatings. During
the tear-down we found a mix of Honda, KTM and Suzuki
bolts, with a few Kawasaki nuts, and then some bearings
that we are positive came out of Matt’s Jeep sitting in the
driveway but couldn’t prove. All these items were placed
in one area—the trash bin to ensure they did not make it
back on the bike during reassembly.
With the tear-down and inventory out of the way, it was
time to open up the engine to see just how involved the
build was going to be. We were pleasantly surprised by
our findings. No, this didn’t mean that nothing needed
to be done. In fact, we completely rebuilt the engine, but
not because of a major disaster, but because all the parts
were just worn out. It happens. We used a Vertex Pro
Replica top-end kit, and when we sent the cylinder off to
Millennium Technologies, the Vertex piston went with it so
they could match the sizes for an exact fit. For the bottom
end Hot Rods makes a kit that includes a complete crank,
main bearing with a seal kit and a complete engine gasket
set. All the gears, bearings and seals in the transmission were in great shape, with the clutch basket showing
minor usage but nothing that would force us to replace it.
The stock clutch plates and springs were replaced with a
Hinson Racing kit, and we decided to use Hinson’s billet-proof clutch cover for some added strength.
Before putting the bottom end together, we took the
crank to Crank Works Industries to have them balance our
crank to the weight of the piston assembly. Balancing is
adding or removing weight in certain areas of the crank
to ensure the weight is in equal balance across the entire
crank assembly. When a crank is out of balance, forces
are exerted in different directions, which leads to wasted
energy, along with potentially increased wear on parts due
to more vibration. Balancing allows for more efficient force
exertion and generally reduces vibration. Crank Works
also trued our crank. This is not the same thing as balancing a crank. Truing is the alignment of the crank assembly
on its straight-line axis in order to get the axial run-out as
close to zero as possible. We decided against any internal
engine performance modification, because the 300 power
delivery is so good in stock form we just wanted to eliminate the vibration factor. We did, however, bolt on a couple of power mods with the VForce reeds and a complete
FMF exhaust system, because we just couldn’t resist.
Once San Diego Powder & Protective Coatings finished
the frame, the chassis went together with all-new bearings from Pivot Works. And while everything was apart,
The complete engine was rebuilt using Vertex, Hot
Rods, Millennium Technologies and topped off with
some Crank Works magic.
The Trail Tech X2 light and Ultra Pro Bend Cycra handguards make it trail-ready, day or night.
Dunlop’s 756EX tire is a cross between a trials tire and a
moto tire. It works great but does not like high speeds.