Forward Motion doesn't offer full scale engine rebuilding services anymore but we do support an excellent company with big bores, porting, and head-work. The company is called Finishline Engines in Beaver Dam Wisconsin.

Finishline Engines is owned by Ryan Callies, a certified BMW motorcycle mechanic and active racer in dirt-track, supermoto, and karting. Ryan apprenticed with Eric Gorr for three years and learned first hand how to build winning engines, 2 & 4-strokes. Ryan still works closely with Eric.

Finishline Engines, 431 Madison St, Beaver Dam, WI. 53916
Call Ryan at 1-(920)382-2897

TWO-STROKE ENGINE REBUILD PACKAGE OFFERS

PERFORMANCE ENGINE REBUILDING Starting at $475

Whether you need a basic bearing and seal change, crankcase weld repair, tranny service, or full race set-ups we have the widest variety of services at the best prices in the business. These services are available for dirt bikes, ATVs, and shifter karts. The typical bottom-end engine rebuild requires new bearings, seals, gaskets, and rod kit. We use American made aftermarket parts from WISECO, MOOSE Racing & HOT-ROD.

Typical Engine Rebuild Packages and Prices

Stage 1 Basic Engine Rebuild $475 to $550

Rebuild engine with new bearings and seals, install new Hot Rod or Wiseco crankshaft, polish clutch basket, hone cylinder, clean power-valves.

65-100cc Labor $200 Parts $275
125-500cc Labor $200 Parts $325

Additional items

New piston kits range from $65 (minis) to $125 (250cc)
New clutch plates & spring kits range from $70 (minis) to $140 (250cc)
Installation included of a Wiseco clutch basket for $195

Stage 2 Big Bore Engine Rebuild $750 to $900

Same bottom end rebuild parts and labor as in Stage 1 and includes a Wiseco overbore cylinder kit and Nickel-Composite plating, porting and head mods.

65-100cc Labor $400 Parts $350
125-500cc Labor $500 Parts $400

FOUR-STROKE ENGINE REBUILD PACKAGE OFFERS

Check out these Tuning Tips on how to make CRF, YZF, RMZ, KXF more reliable and perform better. These tips deal with the top end and valve trains of late model Japanese dirt bikes. At the end of each model section we list the Stage 1-5 kits that comprise our package deals for performance accessories and services. We beat MOTOSPORT OUTLET prices on component parts like Wiseco $150, Hot Cam $180, Athena Big Bore kits $695 and Black Diamond valves $30 and spring kits $200 The Stage Kit prices are all inclusive with parts, labor, and porting so you can just bolt components on your engine or bolt the engine into the frame.

Honda 2004-07 CRF250R/X

The 250 is a high revving high maintenance dirt bike. Its possible to get more low end and quicker throttle response with epoxy-porting ($195). A Hot Cam ($150) will also boost low end. The big problem with the Honda CRF250 is the valve train. The springs aren't adequate and the valves bounce against the seat, mushrooming the valve and seat. Other problems include chipped valve seats and worn exhaust guides. When we receive a cylinder head we disassemble it completely, soda-blast clean, and inspect the entire head and valve train. In some cases its best to buy a new 2006 head ($220) that fits the 2004 & 05 models. The stock 2006 CRF250R head has constricted ports for rapid throttle response. Regarding valve train choices; Kibblewhite makes stainless steel Black Diamond valves and a dual spring kit, ($395) which greatly improves the longevity. Xceldyne is a new company to dirt biking and a mainstay of NASCAR teams. Their new high-end titanium valves are DLC coated and have a high flow shape ($480 set). They're lighter than stock valves and can be used with inexpensive stock springs. The Xceldyne head set-up is intended for the competitive racer that needs over-rev protection. Honda OEM valves are the lowest on the quality scale and have been on chronic back-order since 2004. We try to stock them because they are a cheap alternative to aftermarket valve train parts ($240).

The 2004 cylinder is too thin at the skirt and it will crack eventually. We modify 2005 cylinders ($190) to fit the 2004 model by grinding a groove for the oil spray bar. If you're looking for a big bore kit on any CRF250R/X 2004-07, there are 2 alternatives. The first alternative is a 262cc Wiseco piston that can be fitted to the stock cylinder with boring and Nickel-Composite plating for $425. The second alternative is a Vertex 290cc kit, which includes a complete cylinder, piston and gasket kit for $699. This kit requires crankcase clearance mods, and that means the cases must be split as in a total engine rebuild.

These are the performance packages that we offer for the CRF250R

Stage 1 Kit: Includes porting and valve job with KPM Black Diamond valves, springs, retainers, and seals plus a top end gasket kit $600 Xceldyne DLC Hi-Flow valves and stock springs $775

Stage 2 Kit: Same as 1 with Hot Cam add $180

Stage 3 Kit: Same as 1& 2 with stock sized high compression Wiseco Pro-Lite add $150

Stage 4 Kit: Big Bore Hi-Compression 262cc piston & cylinder, Hot Cam, Porting & Valve Job, your choice of valve train parts, and FREE Installation when you send your complete engine for OEM Honda valve train $1,200 Black Diamond $1,250 Xceldyne $1,400

Honda 2002-07 CRF450R/X

Overall the 450 engine has been a reliable workhorse with cleverly designed features that reduce the chances of expensive energetic disassembly. The weak points are the intake valves and the cam chain tensioner. The symptoms are clacking noise at idle and hard to kick-start. The intake valves tend to get cupped from bouncing off the valve seat. The exhaust valves are made of an inexpensive grade of steel and get corroded from pump gas. The quality of the stock Honda head is good. The valve guides and seats are very hard and wear resistant. The rocker arm and cam bearing are replaceable and can be checked by simply turning the bearing or roller and feeling for knotchy movement. If the fixed bearing on the cam is bad, then you have to replace the camshaft. Hot Cams makes both a Stage 1 & 2 models which feature powerband changes with more low to mid-range (Stage 1) and more mid-range to top end (Stage 2) ($150).

We recommend installing the 2004 and later Honda cam chain tensioner ($45) and Kibblewhite Black Diamond valve train parts ($325) which includes 4 stainless steel valves, 2-stage spring kit with titanium retainers, and new valve stem seals. The cylinder design is excellent on the 450 and requires hardly any service outside of cleaning. However if you're a big guy looking for more low end there are two choices; bore and plate the stock cylinder to 478cc ($425) or buy a complete 500cc top end kit from Athena or Vertex ($695)

These are the performance packages that we offer for the CRF450R

Stage 1 Kit: Includes porting and valve job with Kibblewhite Black Diamond stainless steel valves, dual-springs, titanium retainers, seals, and gasket kit $550

Stage 2 Kit: Same as 1 with Hot Cam $700

Stage 3 Kit: Same as 1 & 2 with stock sized Wiseco Hi-Compression Pro-Lite $850

Stage 4 Kit: Big Bore Hi-Compression 478cc piston & cylinder, Hot Cam, Porting & Valve Job, Kibblewhite Black Diamond valve train parts, and FREE Installation when you send your complete engine for service $1,050

Stage 5 Kit: 500cc Athena Big Bore kit, Hot Cam, Porting & Valve Job, Black Diamond valve train parts, $1,200 Ask About FREE INSTALLATION!

Kawasaki KXF 2004-07 & Suzuki RMZ250 2004-07

This has to be the most unreliable dirt bike ever built. And the good news is we can help you out. The entire engine is littered with an overwhelming design thought process of planned obsolescence. We have many updates for the lower end, but the top end is what we specialize in. The valve train is the weakest link. The stock cams are soft and the edges don't have enough chamfer. Hot Cams ($320) help the situation by opening and closing the valves softer than the stock cam. The buckets tend to form a tiny round spot in the face and eventually they shatter. Kibblewhite makes hardened PVD coated buckets ($140 set 4) that are far more reliable than the stock buckets. The valve train service interval is extended and the engine gets a boost in top end but sacrifices a bit of bottom end. We perform a valve job with porting ($195) because the stock valve job one is horrible, not concentric at all. The bad stock valve job causes the stock titanium valve heads to break over time and destroy the engine. Kibblewhite Black Diamond stainless steel valves make the biggest difference in longevity. For long-term reliability you need all the parts with valves, springs, and buckets ($550).

On the cylinder head, the cams use half ball bearings and half plain bearings. If the oil level or pressure drop the cams can seize to the plain bearings, causing the engine to lock solid. We can usually fix that problem with honing and polishing of the plain bearing.

Regarding big bore kits there are two alternatives; 262 and 290cc Its possible to bore and plate the stock cylinder to 262cc using a Wiseco Hi-Compression Pro-Lite piston kit ($400). However there are some potential problems with big boring a KXF or RMZ250, a well-used lower end has the potential for snapping the connecting rod. Hot Rod makes a heavy-duty aftermarket connecting rod. The tiny oil sump screens clog easily on this model causing a loss of oil flow that usually causes the exhaust cam and buckets to wear in a round pattern. If you have a 2004 model we can improve the gear shifting with the installation of the 05 shift star and plate ($75).

Overheating can be a problem for the 2004 model due to 2 reasons; clutch slippage and coolant flow. When the clutch slips the crankcase oil temperature increases, stiffer clutch springs from Pro Circuit ($50) and Moose Racing plates ($90) will reduce slippage and engine temperature. Regarding the coolant flow, the problem is duo fold; flow rate and capacity. Boyesen makes a high flow waterpump kit ($150) with an impellor and shaped housing that allows you to change the oil filter without draining the coolant. For big bores, engines run in hot hilly climates, Fluidyne radiators ($365 set 2) are a must have item. Fluidyne radiators have more surface area at the core and the frame is very solid and resists bending. Also the top and bottom radiator tanks are oversized and hold more volume of coolant.

These are the performance packages that we offer for the RMZ/KXF250

Stage 1 Kit: Includes porting and valve job with Kibblewhite Black Diamond stainless steel valves, dual-springs, titanium retainers, seals, and gasket kit $700

Stage 2 Kit: Same as 1 with a set of Hot Cams $1,000

Stage 3 Kit: Same as 1 & 2 with stock sized Wiseco Hi-Compression Pro-Lite $1,150

Stage 4 Kit: Big Bore Hi-Compression 262cc piston & cylinder, Hot Cams, Porting & Valve Job, Kibblewhite Black Diamond valve train parts, and FREE Installation when you send your complete engine for service $1,500

Stage 5 Kit: 290cc Athena Big Bore kit, Hot Cams, Porting & Valve Job, Black Diamond valve train parts, lower end rebuild with new crank, bearings, seals, and labor $2,200

Yamaha 2001-2007 YZ250F

The 250 YZF has been a fairly reliable engine but there are some things to pay close attention to. The 2001 had characteristic problems with crankshaft journals being undersized and fast wear to the cam sprocket. The balancer keyways and bearings tend to shear and wear which causes funky noises and vibration. Flywheel keys shear easily which causes the engine to backfire and make it hard to start. If you're a clutch fanner the plates will break and the particles will clog the sump screen causing a loss of oil pressure making the cams seize on the plain bearings. On the top end the titanium valves won't give much notice before the heads shear off and corrosion of the valve seats from ethanol pump gas helps accelerate the wear. We use Kibblehwite valve train parts ($350) and the stainless parts last about 300 hours. Rule of thumb; when you have to install shim pads 3 sizes smaller than original, the ti valves are junk. The 2001-02 models can benefit from Hot Cams ($280 set) because the exhaust cam includes a decompressor so you can kick it like a 2-stroke. The carbs are a source of problems, sometimes they blow off the manifold and the mixture screws vibrate out causing lean popping and low end bogging. You can Super-Glue the carb to the manifold. Regarding the mixture screw don't waste your money on a stock one, buy a Pro Circuit extended numbered screw ($35). At least you can adjust it and monitor if its still in place.

The top end has a ton of potential because there are lots of accessories available for the YZ250F. Wiseco makes a lightweight gas-ported piston in the stock bore size and hi-compression that is great for the displacement racing classes. The 262cc 13.25:1 CR kit ($400) gives more power throughout the rev range. The Athena 290 kit ($650) gives way more low end but goes flat on top end without other mods like porting ($195) and Hot Cams ($290 set).

These are the performance packages that we offer for the YZ250F.

Stage 1 Kit: Includes porting and valve job with Kibblewhite Black Diamond stainless steel valves, dual-springs, titanium retainers, seals, and gasket kit $545

Stage 2 Kit: Same as 1 with a set of Hot Cams $825

Stage 3 Kit: Same as 1 & 2 with stock sized Wiseco Hi-Compression Pro-Lite $975

Stage 4 Kit: Big Bore Hi-Compression 262cc piston & cylinder, gasket kit, Hot Cams, Porting & Valve Job, Kibblewhite Black Diamond valve train parts, and FREE Installation when you send your complete engine for service $1,175

Stage 5 Kit: 290cc Athena Big Bore kit, Hot Cams, Porting & Valve Job, Black Diamond valve train parts, $1,485 and FREE Installation when you send your complete engine for service.

New for 2006 Vertex Piston Co. designs a 270cc 80mm full-skirted piston for enduro and hare scrambles $400 for Big Bore Nickel-Composite plating, piston and gasket kit!

Yamaha 98-2007 YZF 400,426,450

The Yamahas are the best-engineered and longest lasting 4-stroke dirt bike engine. That's the biggest reason why owners let them go so long without servicing. Engine longevity and owner complacency often collide into one big repair bill every 3 years. Here are some tips on preventative maintenance that can yield big performance and longevity gains.

The 1998-99 YZ400F had problems with small end connecting rod breakage so Yamaha increased the piston pin size on the 426 engine. The 1998-2002 models can benefit from Hot Cams because of the auto decompressor makes it easy to start. Aftermarket handlebar-mounted hot start levers make a big difference in convenience, plus you can lean the mixture slightly by cracking the lever open. This might be beneficial in hot weather or riding at progressively higher altitudes. Clutch baskets tend to chip and Wiseco forged baskets are excellent replacements ($195).

On the top end, the YZF likes higher compression but if you ride slow through the woods its likely to overheat unless you install Fluidyne radiators ($375 set). Wiseco makes high compression pistons in stock and 2mm sizes and in stock and hi-compression ratio domes ($150). Generally speaking big bore kits ($400) give more low-end power but go flatter a bit sooner in the rev range. The good thing is it encourages the rider to up shift well before they hit the rev limiter.

On all YZFs the cam chain ($20) should be changed once a riding season to stave off premature wear of the cam chain drive sprocket. That sprocket is part of the crankshaft and cannot be replaced separately. So when the sprocket wears out, the whole crank is junk! A lower end rebuild with new bearings, seals, gaskets, Hot Rod crankshaft and labor ($625) will need to be performed an average of once per 3 riding seasons assuming frequent oil and filter changes.

The cylinder heads have strong seats and guides. The stock steel valves on the older YZFs were stone reliable but the titanium valves from 2002 and later wear out easily causing all sorts of tuning maladies. Even if you use thinner shim pads to loosen the clearance, they'll just close up at a faster interval until they snap. Stainless steel resists corrosion from moisture and unleaded ethanol pump fuels. Plus they can be re-ground at future top end services so they'll last indefinitely. The stock valve springs are cheap at $5 each but Kibblewhite dual-springs are made of chrome silicon steel and run $45 more. You get what you pay for and valve springs are such a critical component you don't want to cheap it up.

These are the performance packages that we offer for the YZF 400-450s

Stage 1 Kit: Includes porting and valve job with Kibblewhite Black Diamond stainless steel valves, dual-springs, titanium retainers, seals, and gasket kit $545

Stage 2 Kit: Same as 1 with a set of Hot Cams $825

Stage 3 Kit: Same as 1 & 2 with stock sized Wiseco Hi-Compression Pro-Lite $975

Stage 4 Kit: Big Bore Hi-Compression piston & cylinder, gasket kit, Hot Cams, Porting & Valve Job, Kibblewhite Black Diamond valve train parts, and FREE Installation when you send your complete engine for service $1,175 Big bore displacement sizes include; 400 to 420, 426 to 444, 450 to 472cc

 

Telephone Orders Call 1-630-825-5645
Email: ericgorr@hotmail.com