G2 Torn Down- Advice Please

[andyleonard]

Couldn't stop the smoke in an '86 G2 with 120 PSI. I tried all the usual tricks with no joy, so I tore it down today and found a scratched bore, scuffed piston, worn rings and hammered valves with rock-hard seals. Obviously I need a rebuild kit and a manual. I see kits for sale for $219. Is that right? And I keep hoping someone will send me a manual jaleonard8@gmail.com . Any tricks I need to go back together? Fancy case sealer? Anything special to pay attention to? Thanks.

[rib33024]

Welcome to BGW

Ask here some one will send it to you


http://www.buggiesgonewild.com/gas-y...-manual-6.html

[andyleonard]

Ordered a kit from BGW on Tues and half the stuff showed up Thurs. With .006 taper and .004 OOR, I honed for a .25mm piston, so I'll fit that tomorrow. The seat on the intake valve was hammered into a groove, so new valves. Everything else didn't look too bad.

QUESTION: My friend's G2 has a T in the vacuum line to the pump. Is there supposed to be a one-way valve in the line somewhere? I don't have one. Could that have been part of the smoke problem?

QUESTION: His motor had been opened before and had a case gasket and had over .030 crank endplay. My motor had never been opened and the endplay was good. No gasket, only sealer. Do the later than G2 motors use a gasket and that's why there's one in the kit? I'm not going to use one.

QUESTION: If the compression was 120 and everything was a mess in there, I'm assuming it will come up to 160-170 when the new rings seat. How much can I cut the head to get it up to 200? .020-.030?

Thanks for the manual. Much appreciated.