Early 70's CCW-Kioritz 500

[KennyRogers]

Hey all,

New to the forums here, winter in Wisconsin has been great for snowmobiling so far. I acquired two very dusty, but great looking (after a bath) JD 500 sleds. I've been in the process of cleaning them up and recently tried firing one of them up. I cleaned the carb - looked fantastic (Walboro carb), good spark with no messing around. I dumped some oil rich gas in the cylinders and turned it over slowly since I figured these things were pretty dry. The carb is pumping fuel well! I was quite surprised.

Put some fresh premix in the cylinder and tried firing it up. I got the engine to turn over a few strokes and sounded good, but the most I am getting am pops and backfires. It's spewing some smoke out of the carb intake. I am not familiar will piston ported two strokes, however I originally thought I had some cracked reed petals. Since this doesn't have any, I am at a loss.

Does anyone have any ideas?

Thanks for any suggestions!

[croyturbo]

I would check for mice in the exhaust.

[JDT]

Crankshaft seals are a must address issue on any engieen that has sat for a few years no matter how clean the rest of the engine or carb looks.

[KennyRogers]

I have not taken off the exhaust yet. I will check it out; there was definitely a lot of mice homes under the hood. I thought I clean them all, never thought they would get into the exhaust though. I let you know what I find.

I was hoping the seals would be ok, but guess I might not be so lucky. Does that require a tear down all the way to the crank?

Thanks for the help!

[JDT]

There are lots of guys sitting in their garages looking at melted pistons who thought that their seals were OK.

Cost less than $10 to replace. It is a no brainer.

Yes, tear down and the correct clutch puller and the correct flywheel puller.

[KennyRogers]

Thanks for info! Soooo where do I buy crank seals for this bad boy?

Also, I got the engine pulled last weekend (probably a summer project now) and I am a bit confused at how to get the drive clutch off. I found an old copy of the service manual online, but it's still a bit confusing to me. For the flywheel, I am assuming I will just use my puller kit.

I could use a little help with the fuel tank too....lots of goo, rust, and smells like someone went #2 in it. Any quick ways to get it squeaky clean?

Thank you again.

[Matt]

Crank seals, one of each, or you can get the complete gasket kit with the seals:
http://www.newbreedparts.com/newbreed/i ... uct_id=115

http://www.newbreedparts.com/newbreed/i ... uct_id=114

Complete kit:
http://www.newbreedparts.com/newbreed/i ... uct_id=158

As for clutch puller, you need to determine if you have a Comet or Salsbury clutch. For the flywheel, if you have a harmonic balancer or steering wheel puller and you get the right bolts, (can't remember what size off the top of my head) you can use that.

You can use oven cleaner inside the metal tanks, and throw a length of chain in and shake it around to knock the junk loose.

[KennyRogers]

Thank you for the info Matt.

I have switched my priority this weekend to getting my Ducati valve clearances checked, then I will tackle tearing down the engine next weekend (or this weekend if there is still time). Looks like it will be a summer project, but it's ok, I still have another sled I need to rebuild too.

[KennyRogers]

Been a little while, but getting around to doing some work on my old sled. I bought a clutch puller based on this post:
http://www.snowmobileforum.com/vintage- ... moval.html

However, I think it's the wrong tool for the 101C drive sheave. The picture in the service manual looks like it has necked down section. The tool I received has a straight shaft.

Does anyone know? I am thinking about cutting a piece of steel and getting a hardened bolt rather than buy another $40 dollar tool.

[400brian]

Some pullers ( perhaps the best ) have a smaller dia tip section, that allows it to go into the threaded hole in the end of the crank, bottoming out and pushing from the bottom of that hole.

The puller that I have used for years pulling Comet clutches off of Kioritz engines is more like you describe. It pushes on the end of the crank, and so far it has worked OK, and has not messed up any cranks to date. I lube the threads, and hit it withe the impact. Sometimes in and out several times, but they have all come off so far.

[Matt]

If you bought and received the one that page linked to on Dennis Kirk, then it's correct, did you try it? I'm pretty sure my Comet puller is straight as well.

[KennyRogers]

It is the part from Dennis Kirk. Yes, I tried it and it bottomed out and came to bear on something. I didn't go too nuts with it, because i was worried I was pushing against the clutch itself.

I have a Dewalt 1/2" drive cordless impact wrench. I will give it a try and see if I can get it off. I was thinking about adding a bit of heat if I find any difficultly.

Thanks guys.

[Matt]

Fill the clutch hole with grease before you put the puller in. It will help push.

[KennyRogers]

Thanks again guys. A little heat and the impact wrench and it popped right off.

I got heads pulled and I'll finish pulling the cylinders this weekend. I have a lot of cleaning to do.

I am also going to need gaskets. Anyone know where I can buy a kit?

[lwb140]

Supermatt can get you all the parts you will need in newbreed parts at the best prices anywhere wade