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The Four Stroke Dirt Bike Engine Building Handbook

Paul Olesen



I hope all of you have been getting out on your bikes and riding as much as possible now that spring is in full effect. For those of you in warmer climates, please don't remind me you have been riding year round without any additional layers, this only makes me jealous and forces me to seriously consider the thought of moving. I've been very busy the past month, but have tried to get a couple hours in on the bike every Saturday. There truly is no better therapy than going out and spanking the bike around after a long week of work!

I'm very excited to announce that the eBook I have been working on these last four months, The Four Stroke Dirt Bike Engine Building Handbook, is officially released. I want to spend a little time talking about what the book has to offer you as a dirt bike engine building enthusiast; I don't think you will be disappointed. Below is a snapshot of the table of contents as well as a few interior pages, just to give you an overall look at what this book covers for you.


What could this book possibly be about that other reference materials, like service manuals, don't already cover? I wrote The Four Stroke Dirt Bike Engine Building Handbook to be an all encompassing guide on engine building. Whether you are building a stock or performance engine, this book provides a specific framework for you to understand and use throughout the entire process. From the moment there is doubt about the engine's condition to the time the rebuilt engine is broken in, I give you a step-by-step guide to help you work towards a successful build. My aim was to create a definitive resource that hit on all the topics you may question as you proceed through an engine build, and teach you the how and why behind the way things are done.

I've been very fortunate to work with talented engineers and builders over the years. This book is a way to share the knowledge I have learned from them with you, a way to bridge that gap for at-home engine builders to enable you to be better equipped with the proper insight and information when it comes time to rebuild. Today's modern four-stroke dirt bike engines are fine pieces of engineering, are designed to exacting tolerances, and require a great deal of care and precision in order to keep them operating at their finest. If you don't work with engines on a regular basis or haven't been taught by a great mentor, there are a lot of subtleties which can be overlooked that I've written extensively about for you.


Throughout the book, engineering knowledge and practical experience are fused together to detail the how and why behind the way procedures are performed, parts are designed, and engine performance is affected. This is the most important and valuable aspect of the book, and it's something you won't find in any service manual. The book doesn't just tell you to bolt part A to part B, it teaches and explains the correct way assembly procedures should be performed and why it is necessary to do so. It also explains the intricate relationship between parts. For example, the interaction between the valve guides, seats, and valves must be understood in order to understand why valve seat cutting shouldn't be left to just anyone. Along with the practical building how and why, an entire chapter has been dedicated to detailing how performance parts affect engine performance. Within this chapter helpful suggestions are provided to aid you in choosing the correct components for your build, depending on your specific riding needs.

If you don't work directly with engines on a regular basis, it is hard to acquire practical experience when it comes to diagnosing problems and detecting abnormally worn parts. Not knowing what to look for when inspecting engine components can lead to improper diagnosis and assembly of an engine, which could still have bad parts in it. I have filled the book with as many photos and written examples of worn or damaged parts as I could so that you will know exactly what to look for when inspecting engine components as you proceed through the build process. This is invaluable practical knowledge, which only comes with experience, and is not something you will find in your service manual.


Now that you have a general feel for what the book is about you may have more questions. One I've been asked a few times now by friends and fans is how can you write a book applicable to all makes and models?

Believe it or not, the variations of dirt bike engine designs between manufacturers are in truth very minimal. Sure, there are physical and locational differences. One brand may use two camshafts while another uses a single cam, or one may put an oil pump on the left side of the engine while the other puts it on the right, but the overall layout of the engines and function of the parts are all similar. I did not write this book with the focus being on the little differences between brand X and brand Y. I wrote this book outlining specific techniques and inspection points applicable to every type of engine you will encounter. The function and the way components interact does not change just because they are physically different or located in different places. This is imperative to understand in order to get the most out of the book. To ensure I've covered the various ways parts interact and can be assembled, I've used two different engines throughout the book as examples and have provided specific instruction on how to deal with assembly differences that will be encountered across the Japanese and European brands.


If you have a thirst to learn more about how your engine works and a desire to correctly disassemble or assemble an engine to professional standards, you will benefit greatly from this book. Whether a complete beginner or a seasoned builder, with over 300 pages and 250 images worth of information, there is fresh and useful knowledge for everyone. There is also valuable material packed into this handbook that doesn't just pertain to the act of building the engine. I include instruction on diagnosing engine problems, sourcing and determining which parts to replace, using precision measuring tools, setting up your workshop, and additional tests and inspections that should be performed when preparing racing engines. If you just want to build your engine back up to stock spec, you are covered. If you want to go the extra mile and prepare a racing engine, you are also covered. In a way this book allows you to choose your own ending by giving you all the tools and knowledge you need to complete your build at whatever level you decide.

The book is available in both print and eBook format. We ship worldwide and offer door to door tracking for overseas shipments. I also created a discount code just for the ThumperTalk community that gives you another 20% off the list price. Be sure to enter the code thumpertalk2015 before purchasing.

Order the print book directly from our website or on Amazon.

You can order the eBook directly from our website and it will immediately be sent to your email inbox. From there you can download it to your electronic device of choice to read or print. You also have the option to just view it online. 

This is one tool you can add to your toolbox that won't wear out and break on you and can be used universally. Thank you for your support of DIY Moto Fix these last few months, and enjoy the heck out of the book!

Thanks for reading guys and have a great week.

-Paul Olesen

DIY Moto Fix - Empowering And Educating Riders From Garage To Trail

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Just ordered my copy and downloaded it so I can print it. Wow. Reading through the first few chapters I am so pleased, very organized and detailed. This is an incredible resource, Paul. Thank you so much for taking the time to put it together.

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Just ordered my copy and downloaded it so I can print it. Wow. Reading through the first few chapters I am so pleased, very organized and detailed. This is an incredible resource, Paul. Thank you so much for taking the time to put it together.

RJ, Thanks for purchasing the eBook! I'm very happy to hear that you are finding the book beneficial and a good resource. Enjoy the book!  All the best, Paul.

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10 hours ago, jakob0045 said:

Hey Paul. Can I buy your book somewhere in Europe?




Hi Jakob,

Our book is not distributed to any physical stores, however, it is available through  our website and we ship internationally.


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17 hours ago, Scott Meshey 141 said:

As someone who is their own practice bike mechanic, this is gold!

Hi Scott, thanks for picking up a copy of my book! It's great to hear the booking is helping you out.

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