A little something I have been working on

[rgvlee]

Pretty much... the ports/casting on the stock barrels is pretty rough, I can see how port/polish can make such a difference. Given there are faults on these barrels my thoughts are next top end on this one will be port/polish and a replate.

No new photos from last night... just lots and lots of cleaning. Chain is off awaiting new one to go on once everything is sorted. Side stand off and cleaned (SHIT EVERYWHERE), also took the stator cover off and cleaned up most of the gunk behind there. Big job.. ran out of cleaner and there is still more to go

Had to get the trusty impact driver out to get the oil pump cover off. I'll be making a trip to a fastener shop on saturday to get some hex head screws to replace some of these oem ones that tend to nip up if they've been left for a while (as well as use some anti sieze on them).

Will pick up some solder tonight for the squish test.

[speed3]

Is there anyone that does porting locally? Anyone got an idea of costs/time etc involved? Going to be swapping the carbies, opening up the airbox and playing with jetting in a month or so. Wouldn't mind at looking at porting as well.

[robwilliams]

Awesome work Lee. Love the whole setup, workshop and all. Wish I had a setup like this for the RG500! Thought I admit, I don't play with the motor! The 500 is about to hit the magical 50000km mark! Still going ok.

[ritza350]

Originally Posted by speed3

Is there anyone that does porting locally? Anyone got an idea of costs/time etc involved? Going to be swapping the carbies, opening up the airbox and playing with jetting in a month or so. Wouldn't mind at looking at porting as well.

is this for the tzr?? if it is get on the tzr uk site, theres a guy on there tells u what to do to the carbs to take them to race spec he says no need for any porting on teezers.....carbs n pipes is the go

[speed3]

You mean TZR?

I'm getting TZ 38mm flatside carbies as it's going pre-mix and track only. Pipes will have to wait a little longer as they aint cheap.

[Sprint]

Another awesome thread... I can only imagine your satisfaction when you get it running

S.

[speed3]

I can't wait to hear it, should be an absolute screamer.

[Stratos]

People in Perth who do porting for 2strokes? I think you have everyone here you would need to talk to about doing it yourself. Id try it, if i had several barrels laying around, which i dont ...

[speed3]

Sounds like too much fuss, especially considering I want to return it to the road a in a year or 2.

[Stratos]

Your gonna need a second set of barrels then? If you start race prepping your bike your obviously looking for power, this is going to degrade your engine life expectancy yeah? Considered getting a second TZR motor? Are you gonna be trying to get your hands on that racing harness? I cant remember what its called but usually source it from Japan. Controls the carbs and makes changing ignition timing easier.

We all need to win lotto or something. Because i want to make a racing Rotax 122 with the flat top piston n porting like fuck at some stage. Lack of sleep is making me dreamy, lol.

[Rob]

Man Love for Lee

I haz it.

[rgvlee]

I promised myself a night off last night, but couldn't resist the urges

Wednesday:
The stator cover prior to cleaning. The photos flatter it, in some parts there was atleast an inch of built up grease and dirt. Even found a leaf tucked away in the grime.




Thursday:
The squish test. Just for you stratos. The squish on this top end is 1.14mm, which is good as the stock is 1.2mm. Better results are gained when you start getting down to 0.8-0.9mm but for now this will do. Later on I can change the insert to get more squish. So based on this I don't expect much HP gain from the heads.




Some use two bits of solder running perpendicular to each other (like a cross) to get 4 reference points. You don't need to. The important thing is to place the solder along the gudgeon pin. If you place it perpendicular to the gudgeon your results will be skewed as the piston will tilt slightly on the gudgeon. When we are talking fractions of a mm this is important. It's also important to torque the heads correctly. I ended up doing two tests on each cylinder (because I am pedantic).

For reference I ended up going to Bunnings for the solder. Dick Smith Electronics only do up to 1.0mm solder but Bunnings stock up to 3.0mm. I got 1.6mm for this test.

Providing I can get beer for the beer fridge (important! can't work in the shop without beer!), I'll be back in the shop tonight cleaning again and will start to look at bolting up the carbs and water hoses.

Cheers

L

[Stratos]

Awesome Lee, thanks for that. When i finally get around to doing the BBK ive been wanting to do ill be doing it very throughly and this will definatly be one of the tests, ill be documenting it all too!

They look like flat top pistons are they? I didnt know the cougar heads were flat top?

[rgvlee]

Yes, flat tops, and the cougars are designed for them. Stock and aftermarket pistons for the rgv250 are all flat tops.

[rgvlee]

Well I had planned to work on the bike this weekend, and as luck would have it these plans went to shit. I was only able to get out there on Sunday and it turns out this was not enough time.

These were the few parts I was waiting on... new springs and spring retainers. The ones that came off the bike were a bit crusty.


Test fitted the new water hoses. Niiicceee


And this is what I spent most of Sunday doing... cleaning. Still a bit to go but it's starting to look good.


I did actually get some work done. Powervalve shafts and associated bits and pieces now fitted up. Kit powervalve covers on too.

[kwakas]

looking good

[rgvlee]

Just ordered the main jet version of one of these

Flo-Commander by Performance Design

Basically will allow me to change main jet size by turning a knob on the outside of the airbox... so no need to remove tank, airbox, drain and remove carbs, change jet then reassemble. Should make jetting a lot easier. Will be fitted before hitting the road.

Cheers

L

[speed3]

that's pretty sweet

[ritza350]

that last pic looks like lee paying homage to "GOD RGV"

[Satan1]

Great work lee, top write up too!