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1487cc Turbo 2nd Edition

154K views 701 replies 77 participants last post by  coastrider 
#1 ·
I decided to open a new topic to entertainment you with my 2nd edition engine build and
raise some useful discussion up about a Revolution pushed to it's limit in street use.
My target is 250rwhp@7500rpm 185 ft-lbs@5000rpm, but especially I'm trying to improve reliability, which has been the problem. I'm fustrated to open the engine every 3000km.

So, here we go....

CP Pistons are the old ones, driven 6000km. There are couple of scratches in a skirt because of flying bearing pieces in the engine. They are measured and polished to prevent carbon building to the top. Compression ratio is a mandatory in my case.

Has somebody seen somewhere forged pistons for 4.25" (12:1, 1/4" stroker offset pin)?

New piston rings and at this time end plays are adjusted smaller than previously.

1st 0.60mm
2nd 0.70mm
oil ring 0.35mm

Old K1 rods, new bolts. There are marks of flattened and spread pin bushings under pressure. Pin clearances are still okay, but too narrow or soft pin bushings will be a problem in the future. Better pushing material will be needed some day.





Wiseco cylinder liners are used ones. They are measured and re-honed to RA12 recarding CP's instruction for Ductile moly rings.






Falicon 3/8" stroker full circle crank. As I know there are two types of Falicon full circle ctranks in the market.
The other one is with an open rod pin and an other one with blugged rod pin, like mine. How are oil drillings when the rod pin is nod blugged. Does somebody know what is a backround for changes?
 
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#285 ·
Karzza can you show picks of BOV being attached to the plenum.
 
#286 ·
Here You are, but not much seenable.

Thread in the plenum is G1"
Original thread in the Forge BOV is M34x1.0

I desided to re-thread the BOV by G1", to direct fit it to the plenum.

You can use 1" 90deg hose fitting from hardware store and a piece of hose to fit an universal BOV. That was my original plan before I found the compact Forge BOV in the pictures.

 
#290 ·
If you made an adapter will it allow the BOV to fit or is the Battery in the way?
 
#287 ·
Welding of a charge pipe wasn't wery deep. The pipe did crak while I was polishing it. Need to re-weld it, did waste a lot of time. Caused also couple of dents. No good.

 
#288 ·
Good thing you have long winters up there :D
 
#289 ·
The only good thing because of winter is a long snowmobiling season. A Biking season is starting in May and boating in June. It's tuff to try to make business with those short season equipments.
 
#293 ·
The renewed technical department is finally ready:D.


Asked help from Chris at DaytonaTT for E85 basic parameters.
Someone using E85 with DTT VRFI gen3?
 
#302 ·
Asked help from Chris at DaytonaTT for E85 basic parameters.
Someone using E85 with DTT VRFI gen3?
Zero E85 support available from DTT :mad:
Defining of 3D tables is a piece of cake, but all the values for 2D tables and extended parameters would be a big job. Have to reconsider.
 
#295 ·
That's true :moon:

The cracked charge pipe is re-welded. I will polish it on Saturday and then ...wroom-thsi-thsi-wroom.... :D
 
#296 ·
While you are at, make me an adapter!!
 
#297 ·
I will check.
 
#300 ·
Did a half day job to sand and polish the re-welded charge tube. The tube cracked again while I was installing it. Strange. Re-welded it and desided not sand the welding at all. It is what it is. I can't do better:banghead:.
Installed new low profile signal mirrors. Looks better than HD's.

Did a short test drive with low boost. The new turbo is spooling wery early, something like 2500rpm.

A 8deg raked front end doesn't make a difference, except the bike is 2" longer and 21" tyre is not so tightly towards a radiator.


 
#301 ·
#303 ·
Well I don't know what the minimum AF ration in the DTT is. I imagine this is going to take some time with the turbo. I remember alcohol running best around 6.5:1 with 18:1 compression and some more advance. Probably best to hookup with a dirt circle track guy. They run a lot of alcohol cars although the 15% gas will skew the ratios somewhat.
 
#304 ·
The summer has finally arrived here and snakes are awaken.
Did catch couple of them and made a saddle cover :D.



...have to admid, I didn't make it by myself.
 
#305 ·
...the clutch is slipping again >5700 rpm at 5th gear :mad:



A boost collapses when the clutch (or a tire) loose and the engine flies.


Some more torque at 14psi did appear because of the new Plenum, The engine feels like a Tdi :D.
I'm still using gazoline, haven't had time to play with E85.
 
#307 ·
I started 4th round with injectors, because of E85 at this time.

From left:
Stock injector 35lb/hr (4bar)
Siemens DEKA5 80lb/hr (3bar), 103lb/hr at 5bar
Bosch EV14K Compact 96lb/hr (3bar), 124lb/hr at 5bar

Bosch EV14 has 20deg cone spray pattern

 
#310 ·
Somebody was asking how to modificate KMS 300KPa MAP for stock location. Here is it.
 
#311 ·
And here is the G 1" re-threaded Forge BOV for K&M Plenum.
(RSC, it is a piece of cake to modify it, really)
 
#312 ·
Bosch 124lb/hr injectors and
Bosch 5bar regulator are sitting in HD's fuel rail.
A new injector harness was needed.
Injector clips are hand made as well.

Also did re-thread the pressure gauge connestor to 1/8" NPT.
Now it is more useful, for example to pump E85 out before a winter storage.

 
#313 ·
The new saddle is finally here. A lady at Customs was not happy because of a snake leather.
Looks unique:D



 
#314 ·
I like it :thumb:
 
#315 ·
A while ago I was thinking Walbro 255LPH is an overkill.

At the moment I have 2x 124LPH injectors at 5bar + 1bar boost,
and 255 LPH Walbro is far behind of the needs of E85 fuel.

So the next step is 416LPH, which is giving 268LPH at 90 psi, asking 19.1 Ampers at 13.5Volts
Is it a final overkill? :)

http://www.full-race.com/store/fuel-systems/fuel-pumps/walbro-416-lph-in-tank-e85-fuel-pump.html

http://www.finjector.com/verkkokaup...l_pump_416_l_min_with_pre_filter-p-149396-21/


Waiting for a point to need a stronger alternator :deal:
 
#317 ·
A while ago I was thinking Walbro 255LPH is an overkill.

At the moment I have 2x 124LPH injectors at 5bar + 1bar boost,
and 255 LPH Walbro is far behind of the needs of E85 fuel.

So the next step is 416LPH, which is giving 268LPH at 90 psi, asking 19.1 Ampers at 13.5Volts
Is it a final overkill? :)

http://www.full-race.com/store/fuel-systems/fuel-pumps/walbro-416-lph-in-tank-e85-fuel-pump.html

http://www.finjector.com/verkkokaup...l_pump_416_l_min_with_pre_filter-p-149396-21/


Waiting for a point to need a stronger alternator :deal:
JEEBUS! I think you need that now!
 
#318 ·
The Bike won a 3rd prize at Helsinki Bike Show in a "Custom Class".



Technically it is a crap because of a valve-ticking, have to adjust the to get the noise away.
It runs like an animal:D.
 
#321 ·
I hope that brown hideous Kayak with wheels beside your bike wasn't one of the winners... :barf:
It won the second prize in the same class. It is a VW beetle based side car and moving soon to USA. You will see it in your magazines there:deal:.
 
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