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Gonna pull the header and do a quick leak test before plug chop runs. Do I need to use a new crush gasket when putting the pipe back on or will the "old" one likely still seal good? Old gasket is only 2 tanks old since recent rebuild. Wisdom appreciated.

Absolutely re-torque cylinder, head, and exhaust nuts after heat cycles. Ken did my top end and I followed his video on heat cycles. Also took it very easy first full tank and ran a fat main to start. Now starting third full tank and ready to plug chop for final jetting.

Plug I got from local Lowes works great on my stock 06 exhaust but not so good on my KOR ported cylinder. After port job the exhaust goes from round to oval just inside the exit and the plug doesn't want to grip good all the way around. I use a piece of old tire tube under the flange to seal...

Ken did my head and ported the cylinder, I added an FMF and opened the airbox, premix and a 320 main (not yet dialed in). I have two machines, the other one is bone stock, and they ran pretty similar before the mods. You will be amazed at the performance increase. The engine sounds so much...

I rebuilt a bone stock 88 this winter. I can't tell you how many hours the PO put on it in almost 25 years, but I can tell you the stock tires were worn out and the second set had considerable wear, brake pads, sprockets and chain had all been replaced multiple times (box of old parts), frame...

Finished the 88 build in my signature, did the heat cycles, one tank of easy riding, now on the second tank and letting it run a bit harder (OMG its a damn rocket). Planning to plug chop for jetting soon, all has been great so far, easy starts, smooth running. Riding it gently on Sunday, I...

I used an extra washer on the stud large enough to drill a small hole in it. Works fine.

Flywheel side seal is pretty easy, but you definitely need the puller. If I had it to do over I would have sprung for the flywheel holder as well, I homemade a holder with a 2by4 and a couple bolts, which worked, but the right tool is always preferrable. The flywheel nut is gonna be on there...

OK laugh if you want. My quads share the pole barn with a half dozen chickens, and along with the chickens come mice. Lots of mice. I've gotten tired of cleaning chickenfeed and sunflower seeds out of the airboxes. Bigger fear is the tailpipes, I always seem to be forgetting to put the...

Blaster89- I completely agree. My son completely disagrees. Go figure. We're pretty careful and usually ride together but you're right danger is always just one wrong move away. Helmets always and some more gear might be a good plan..

The swingarm is a +4. I was told I'd need a 100 link chain, and had just bought a new 92 link. 100 is too short, need 106-110. Paint is all Rust-oleum, bare metal primer, gloss protective enamel, and clear gloss. It's still not clear if my son gets this one or the 06 stocker to ride, but dad...

Also did A-arm bushings, a KOR case saver, and a TM designworks chain guide. New red handlebars, and replaced the twist throttle with a proper thumb throttle. Going to vent the airbox and cover the vents with the Outerwears material they sent that will not fit over the whole airbox.

So to make a long story shorter, here she is, complete except for chain (bought two new ones that didn't fit, no joy). We did a set of Awk's rear hydros - work great easy install, Awk was a big help with all this. We also did: new front wheel bearings and seals, FMF fatty, oil injection...

Putting the top end back together, keeping it clean. Motor back in the frame, built my leak tester (nice sticker huh?). Funny as hell buying tubing and plumbing parts at Lowes, and the young kid who was helping find stuff just keeps smiling cause he's dead certain I'm building some sort of bong...

So then the good stuff comes to the door. Wiseco 66.25 piston kit, with OEM gaskets. Unfortunately the kit did not come with piston pin clips. After a bunch of calls to Ken and Awk, I wound up finding a couple NOS clips at a dealer only a couple hours away, they measure the same and worked...

Replaced the plates with a Tusk clutch kit, and used 3 of the 5 heavy duty springs, per Ken Oconnor's suggestion. Lever pressure is manageable. The baskets showed some wear, but were'nt notched deeply enough to weaken the fingers. I glued 400wet/dry on some popsicle sticks and cleaned up all...

Yeah I noticed the hacking on the transfers, and thought somebody had taken a stab at something, not sure what exactly. It might be somebody did, but this is a very early 1988 machine, serial number puts it at like 1900th build, which is crazy early, and maybe they were still doing some hand...

We finally found a frame local enough to drive up to Michigan to get it. Turned out the fellow is a well known swingarm builder, and we would up coming home with a new +4 swinger and the frame. We stripped that frame like 3 times, finally gave trying to get all the tight spots and took it to a...

Carb was completely lacquered up, pretty amazing it ran as good as it did. After all the mods, the stock main 220 jet was replaced with a 320, we'll see how that works. Photo of the motor with the top end off, I used masking tape and a sandwich bag over the connecting rod to keep it all clean...

Here's the boy helping tear down, and doing some JB weld on a small hole in the case on the stator side. Despite a virgin bore and original piston, somebody had been in to both sides, looked like they used a homemade tool to hold the flywheel, slopped a lot of yamabond around.