Templar X motor rebuild journey

[Zooker89]

So, with the news that the vendor is sending me "something" to get my motor repaired, I thought I would start a pictorial journal of the rebuild.

The attached photo is for my reference as I begin this. I have done a handful of two-stroke top ends, but never a four-stroke.

For those of you who talk about the need to check every bolt and Loctite it, I can assure you the motor mounts on mine were tight....

So tight in fact, that I split a 13mm socket trying to remove the lower, front mounts. I had an 18" breaker bar on it as the ratchet wasn't enough. I have never broken a socket before (this one was old-school Craftsman). Going to get some impact sockets to try again... Might need some heat!

I am still planning on getting a whole new motor, but plan to attack this one anyway.

[Megadan]

my front motor mount bolts on my Hawk were stupid tight like you describe. My rear mount bolts weren't tight at all. Chinabike lottery.

[Zooker89]

Day two....

So, I borrowed a compression testing kit from a co-worker and it confirmed my original instinct. No compression at all...

I wasn't able to get new sockets as I am in some of the busiest couple weeks of my year at work.

No news from the vendor about a delivery time frame for my parts anyway.

I plan to order a new motor tomorrow. Funds are here...

[Zooker89]

Day three...

I got a set of impact sockets and was able to get the front mounts off.

I got confirmation of parts being shipped. They are due on Tuesday the 6th.

I plan to order the other motor tonight. I hope it comes quick as from being in New York riding season is short....

[Zooker89]

Day four....

I got the motor free'd up, removed the rear brake lever and thought I was ready to pull it out. I cannot wriggle that thing out for the life of me....

Do I need to remove the swingarm and pull the rear motor mount out in order to remove the motor???

After taking the the timing chain cover off, I snapped a pic at TDC then rotated the crank 360 and took another. I got two different positions of the top cam sprocket, which I expected. Neither of the positions made much sense to me as no marks were lined up with the arrow on top of the valve cover. The one where the "0" is on top, it is slightly behind the mark (retarded???). Not sure what to think here...

[Zooker89]

Day four 2.0...

I had time and frankly am impatient with my limited time, so the swingarm and shock came off and the motor slid right out.

Now I need to figure out the cam chain tensioner without buggering it up.

Today's posts brought to you by the distraction I needed from my frustration...

This bike, while I love it, is a genuine Chinese puzzle all on its own...

Definitely more confusing than any other of the dozen bikes I have owned

[Zooker89]

Day four 2.6357...

So, the cam chain tensioner is fairly simple. I got the head off and it appears to me the intake valve had an issue contacting the piston. I will assume after a bit of riding the valve bent and seized.

I cannot tell if the sooty appearance of the top of the piston is from the many times I tried to restart, not only to get home, but to prove there was issue for the vendor.

[Zooker89]

Day five...

Parts arrived. I got the bottom cylinder, top cylinder with the valve train installed and a complete gasket set. I have reached out to the vendor for a manual for the motor. We will see if I get anything. I couldn't find anything worthwhile on the webs...

There was no paperwork for any of the parts.

Once disassembled the top cam has about 115 degrees of free-play. I am not sure if it should be timed with it fully engaged or before.

I am assuming since the valves are both closed on the bench I can adjust the valves prior to assembly. Any thoughts on this?

[Zooker89]

Day six...

After receiving the parts, I asked the vendor for a manual for the motor. This is the quoted response to my request:

Sorry,we do not have the manual. The piece need professional mechanic to complete the repair work as it is not easy job. ​If you can not do the job yourself, please check if you can ask a friend or neighbor who know mechanics for help. ​
Thanks a lot for your understanding.

This was a little infuriating...

After watching a handful of videos on the assembly of what appear to be very similar motors, I have begun. The new piston is assembled and on the connecting rod. Valves have been adjusted. Hoping to get time this weekend to put the rest together.

Does anyone know a compatible crush gasket for the exhaust? I took some measurements of the crushed one, but not much popped up in searches.

[Zooker89]

Thanks jc, I have reached out to them. Waiting on a response, but not holding my breath. I was also going to look for the specs on comparable Japanese motors and see if there is a similarity in specs and just go with that.

I do believe I have the timing all set and have the motor completely back together, but not torqued. Getting the cam chain back on is a PIA. Not much room to work in there...

I ran the motor through a handful of cycles manually and all sounds good and it feels like there is sufficient compression.

[Zooker89]

Day 7,8 and 9...

I haven't had much time due to work....

Got the motor back in the bike, the rear end back on and some small miscellaneous stuff done, but ran out of Loctite so I need to get some and torque everything down. Once I get it back together I will fire it up and see what happens.

It has been almost a week and I have heard nothing from my outreach to Zongshen.

[Sportbike83]

Have you considered swapping to the 4v air cooled 250? I think its the CB250r engine. Its a little pricey but the mounts look about the same. If I blow mine up that's my plan.

[Sport Rider]

There's a lot to know, even with a simple motor like these. I'm not sure I could have done what you are doing. good job!

[Zooker89]

Originally Posted by Sportbike83

Have you considered swapping to the 4v air cooled 250? I think its the CB250r engine. Its a little pricey but the mounts look about the same. If I blow mine up that's my plan.

If I could have put the 300cc liquid cooled motor in, I would have done that, but it doesn't fit. I am not unhappy with this motor. Just want it to run.

[Zooker89]

Day 10...

So, I got everything needed for it to run buttoned up. Put fresh oil in it, connected the battery and crossed my fingers.

When I hit the go button with a little choke, it fired right up! It sounded so good. I just needed to adjust the idle a little bit to slow it down. I let it idle for about 5 minutes and cracked the throttle a few times. Response was good and it settled right back sown to a consistent idle.

After about an hour, I tried again. No choke and it fired right up with the same results as the first time.

Now I just need to put the chain, rear brake pedal, shifter and a few cosmetic pieces back on to take it for its second maiden voyage.

Fingers crossed again!