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I second the initial assessment. Investigate the manifold by removing it from the engine and inspecting it closely for cracks. If there are cracks, and they are minor, you can try coating the OUTSIDE of the manifold in silicone 'caulk' as a test procedure. I actually ran a manifold like this for a couple weeks until a replacement could be procured, and it was still working fine when I swapped it out for a fresh one. I kept the 'old' one in a small zip-lock bag of used, but 'known good' parts that I've replaced (CDI, coil/plugwire, sparkpug, manifold, etc) under the seat as 'road spares'.

Could also be a dirty/plugged main jet.

I have been known to use the boxed end of a straight wrench in the past, because it's rounded and won't tear the rubber. The bigger ones (15/16", 7/8", etc.) are about the right length for the needed leverage without being too 'thick' in the shaft, and the rounded 'box' end is angled, so it helps when trying to 'grab' the edge of the tire.

One trick I learned (and keep having to RE-learn ) is to make sure both beads are busted loose from the rim, and that the bead on the opposite side of the tire you are working on is situated in the deepest part of the rim groove down the middle. The extra inch or two of offset makes it SO much easier to get the bead you are working on up and over the rim. I almost destroyed a rim the first time I learned this, because I was dead set on having the offside (first) bead 'seated' before starting on the second bead. Once I gave up on that idea, and let the offside float in the valley of the rim, the second bead slipped over the edge like buttah.

Those are the engines that allow for the really BIG big bore kits without machining, yes?

Huh. A parallel twin, 2 cycle engine. Not what I had in mind, but interesting none the less. I bet that thing makes insane power for it's package size.





I had thought of that, but really I wanted to avoid the rocking and vibrations of a quick 'one-two' double thump of power strokes inherent in alternating twin, four cycle engines whether they be flat, V, or parallel (and yes, I'm aware of a few mfg's. who make parallel twins where both pistons move in tandem (Honda Rebel 250? ), but the cranks require LOADS of counterweight, as well as additional counter shafts to eliminate the inherent vibrations issues, and weight is a major factor in my plans). In a boxer engine both pistons share the same stroke direction relative to the crankshaft and each one counters the inertial mass of the other one throughout the cycle, which inherently smooths out the operational vibrations, not to mention it simplifies the ignition system since, like the GY6, it can fire both cylinders off the flywheel on every TDC...no distributor needed.




Um, yeah...no. Triumph already makes an inline triple, but it's water cooled, and..well...to be honest I'm not looking for a physically large overall engine size. I realize BMW already makes an air cooled boxer, but again...it's larger (both physically and in displacement) than I had in mind. Somewhere between 300 and 400cc in a lightweight, air cooled, four-stroke boxer is what I'm after.

(I'd really be in heaven if I could make it Diesel...but OY VEY!...the engineering! )

Not really. Here's what I'm talking about;

This is a photo of the rod/bearing/journal parts


As you can see the rod has no 'traditional' end cap, and the journal is not an integral part of the crankshaft, which tells me that the two sides of the crank (with the counter weights and the output shafts) must be assembled onto the rod journal somehow.

Here are two photos of the crank/rod assembly...one from each side




You can see the ends of the rod journal in each view, but I cannot find any information as to precisely HOW they are assembled into the complete unit. I can find all sorts of diagrams and photos of completely assembled units (like what you linked to), but nothing like an 'exploded view' showing all the parts, but *not* assembled.

1,1,1, trichlor is ideal...but since it's no longer commercially available, Brake cleaner works a treat!