Thanks for all your help with the powervalve cleaning info, but I gave up this time. What I do have is a very clean exhaust system having taken the caustic soda to it, wow its evil stuff!

I put it all back together and was surprised at the lask of positive location of exhaust pipe to port.

Then it wouldn't start or fired very briefly and stopped.

Looking at the japanese manual it apperas that I'm lacking a spacer / gasket? There's a metal ring sunk about 5 mm into the header pipe but I can't imagine thats the missing item.

Question: Is there a spacer / gasket missing? - where can I get one and would this poor sealing / lack of back pressure be likely cause of the non starting - it used to work before I took it pieces (how often have you heard that)

ozzychris wrote:Thanks for all your help with the powervalve cleaning info, but I gave up this time. What I do have is a very clean exhaust system having taken the caustic soda to it, wow its evil stuff!

I put it all back together and was surprised at the lask of positive location of exhaust pipe to port.

Then it wouldn't start or fired very briefly and stopped.

Looking at the japanese manual it apperas that I'm lacking a spacer / gasket? There's a metal ring sunk about 5 mm into the header pipe but I can't imagine thats the missing item.

Question: Is there a spacer / gasket missing? - where can I get one and would this poor sealing / lack of back pressure be likely cause of the non starting - it used to work before I took it pieces (how often have you heard that)

The metal ring you have seen ,is a compression gasket, this is soft metal ring gasket and it's always best to renew this after taking off the exhaust system .
Have you checked the plug since your de coking session ? it could be as simple as some mung fouling the plug .
Whilst not having an effective gasket might make the exhaust very loud, and run some what sickly it should still fire up and run, so you may need to double check the power valves reassembly and movement stroke to confirm smooth operation.
Regards Mike

Thanks for the info about the compression ring - mine definitely missing, does anyone know where to get them? it may be easy for you guys in the UK but Australia seems a back water for anything slightly unusual.

I can't find any mention of them on Leisure Trail website.

Oh well, time to throw another shrimp on the barbie and relax in the pool with a cold one whilst I contemplate shoe horning a CR500 motor in, I'm sure it'll fit?!

Chris

Leisure Trail don't list everything they have for CRMs on their website, so drop 'em an email (as you're 12hrs, or so, ahead). They're reasonably prompt at replying.

There's a store at liverpool called bikeparts, next door to red baron motorcycles. They got me spare gaskets for when i did my rebuild.

Another store that supplied me with a full gasket kit was All 2-strokes (i think that's their name) at windsor.

If you need pistons, rings, gudgeons, Wossner in Perth do a nice piston for $190.00.

If you need any more info, let me know, i've got a relatively good list of people now (i dedicated 2 weeks to digging up as many suppliers as i could)!

Forgot to mention, All 2 strokes had the gasket kit in stock!