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generatorshovel
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Date Posted:05/19/2007 8:15 PMCopy HTML

Well, I've given up cigarettes to fund the salt habit, and things are moving along smoothly.The FZR head and barrell lost No4 cylinder,(Yamaha's loss, Honda's gain)the water galleries and oil returns have been plated, the crankcases are nearly finished their stay @ the welders shop and will be decked soon (its a "laydown" engine now.aka ct110 style), the crank has been modified to take the FZR rod (slipper big end bearing), the piston (FZR) is booked in for a ceramic crown coating, and I've contacted a friend who'll balance it all for me.The FZR cams have been shortened, with2 ofNo3 cyl's lobes being reduced to a 23mm circle where the oil seal will run , and the other 2 lobes are gone, leaving a 22mm camshaft extension to be used with outrigger bushings which will double as the oil feed to the cams.The belt pulleys are on their way from Gates, for added "bling"CDI ign is on the wish list (Boyer Bransden,,$700,,ouch, with adjustable rev limiter and special coil)Dunno 'bout it being ready for 2008's timetrials, 'cos I need to build a new frame yet, and source some better wheels, and speed rated slicks,,and so on , and on,,,,,,but,,ya never know? 'till ya try.Tiny
generatorshovel #61
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:03/05/2009 6:37 AMCopy HTML

The day of reconing aproaches,,,,,in 12 hours I leave to head to lake gairdner for speedweek 2009
The little fella has survived a good flogging, including 11,000 rpm wot on methanol,,all that remains now is to get a +85 mph time slip next week
Tiny
Motoracer838 #62
  • Rank:Gold Member
  • Posts:121
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:03/05/2009 5:02 PMCopy HTML



Good luck!!!

Of all the things I've lost,
I miss my mind the most. Joe
generatorshovel #63
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:03/14/2009 7:47 AMCopy HTML

It looks like I'll have to wait another year
Big end oiler failed @ 250 yards, that equates to $1 / yard,+ repairs,lol,, good job I'm a patient kinda bloke
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/speedweek%2009/problemfound.jpg[/IMG]

[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/speedweek%2009/09postieonlake.jpg[/IMG]
Tiny
generatorshovel #64
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:03/27/2009 12:03 AMCopy HTML

Another pic, 250 yards before failure hit.
generatorshovel #65
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:05/21/2009 2:44 AMCopy HTML

There has been movement in the sus'n'repair station,,,the lil beastette has migrated from the shed the wife banished it too, and returned to the creation station

Progress will be posted when it takes place
Tiny
generatorshovel #66
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:08/03/2009 11:01 AMCopy HTML

It's been a while since the 'ol girl developed her sickness, I went looking for the damage the problem had caused, this weekend, and found another BIG problem.
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/spunsleeve.jpg[/IMG]
The original problem wasn't as bad as expected though.(the bigend bearing shells are shown in the pic above)
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/crankpin.jpg[/IMG]

It was a good opportunity to replace the broken kick starter return spring, but , unfortunately the two I bought don't fit,,,anyone need a pair of NEW XL 125/175 kicker return springs?
Has anyone have a supplier of CB125 kicker return springs they recommend?
Tiny
surffly #67
  • Rank:Silver Member
  • Posts:59
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:09/15/2009 2:51 AMCopy HTML

great work on a super cool project. 
any new news?
generatorshovel #68
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:09/17/2009 9:24 AMCopy HTML

Update,,,,Re-assembly time,,the stuffed cam bearing casting has been machined out and a needle roller bearing has replaced it, luckilly, the cam survived the ordeal, and by chance,,there's 30mm 'tween the cam cap dowels and the bearing is also 30mm OD, phew,,,,
The crankpin also survived, just needed linishing and the conrod and bearing shells replaced (the 'rod had 2 gold heat discolourations @ the top and bottom of the big end area) , luckily I had most parts needed "in stock"
Thats the good news.
The bad news is Iv'e thrown together an XL175 engine using the modded head from my original engine (closed chamber XR200) and put it into a raked and lowered VT250 frame, with XR200 wheels for a friends 15 y/o son to race next march, and on its 1st test run, it topped out @ 88 mph ! before running out of road, on pump gas,,,,wait 'till the 13.5/1 compression ratio gets some alcohol to burn !, why bad news you may ask ?,,this bike will compete against me in the MF/175 class, and looks as if he'll flog my existing record,,lol.
Tiny
generatorshovel #69
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:09/23/2009 8:13 AMCopy HTML

FIXED !
[IMG]http://i156.photobucket.com/albums/t24/generatorshovel/fix.jpg[/IMG]
Franklin_Speedy #70
  • Rank:Bronze Member
  • Posts:39
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:11/16/2009 5:43 AMCopy HTML

WoW.   looks like burt munro's gost is with you.   im happy to see a one off custom LSD small cc machine.

since your last posting how is it coming along. i havent been on in along time. been working on some projects never got around to the web forms. I got near 90mph on my CB125S cafe road racer. still working out some bugs. and trying to get to my goal of 100mph.  making things lighter, and trying to make it last over 12k RPM.

well its near that time of yr that i get down and dirty and make parts and upgrades to my little honda.

Swiss #71
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:11/17/2009 12:54 AMCopy HTML

Speedy,

Give me the specs that you have on your 125 and maybe we can see about thinking up some mods to help reach 100mph!

Swiss
generatorshovel #72
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:11/18/2009 9:52 AMCopy HTML

Speedy, what did you end up using in your engine ? did you go with the CRF bits?
I finally have evrything I need to complete my rebuild / oil feed re-route / repair.
I found some ultra hi pressure stainless 5/16 tube to machine a new big end feed from, no more risk of snapping the end off due to the ID limits (I used a .22 rifle barrel last time) but just incase it does, Iv'e gone back to a splash fed timing side main bearing (like XL's use) , which blocked the C B crank's oiling hole (where most of my big end oil went on the salt)
Actually, I found the hi pressure stainless twice,,,the 1st was in the USA, but wanted $70 to ship 4" of it to OZ
too bad,,one less sale for those fella's (pitty , 'cos with a 3mm ID,,it was purrrfect.

I ended un getting 8" , with a 1.7mm ID, which will have to be enlarged to 3mm , but using the existing bore as a guide, this shouldn't be a problem.

Its just TOO DAMN HOT here to get serious in the creation station,,its 7.50 PM now,,and still 106 degrees outside, and the concrete floor in the shed has soaked up a week of 100 + temps , add to that,,the f/cast for tomorrow is 116 degrees

In my spare time, Iv'e slipped the closed chamber XR200 head from my '06 postie bike onto an XL175 engine I had laying around, slotted it into a VT250 raked rolling chassis, with '80 XR200 wheels (21 front) , for a friend's 16 y/o son to race next year.
The comp ratio ended up @ 13.5 / 1 , and on its maiden voyage, while being chased by dad in his car, spun to 10,000 and 88 mph in top, with some speed left in it !!!! , this is on pump gas !,,it's now rejetted for fuel and almost ready for another run.
Because its a real pain to start, with the comp. ratio, the folding kicker folding at the wrong time, the fold down brake pedal that flops down after each kick, but always flops up, when ya need to stop,,Ive made a honda stationary engine powered roller starter, using a postie bike centrifical clutch, a XR100 mainshaft, honda 90 primary drive gear and the end of a 90 crank,and a 10" go-kart wheel,, a real work of art, lol.
 The trouble still lieys in the bikes compression ratio, and the bike needs to be in top gear to turn the engine over,,but,,as the stationary engine is only 120cc, and the bigger model of the same engine is 200cc, and had 33 % more power, and supposing they share the same bottom end, the plan is to make a "D" to round carb adaptor, throw on a 125 honda cark, drill the crap outa the main jet, throw some methanol in it, add 5% nitro methane, walah ! 33% more power,,for how long,, I dunno ?
Tiny
Swiss #73
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:11/18/2009 6:55 PMCopy HTML

Tiny, when is your race season for the top speed run?

Swiss
generatorshovel #74
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:11/18/2009 10:37 PMCopy HTML

2010 SPEED WEEK - 8th - 12th March 2010. Swiss.

There's going to be 2 tracks next year (if we can get the man power to set up etc ) the new track will be 3 miles total, with 1 mile run up, but, GPS speed logging only, and no new records can be set using this track.
The idea behind the 2 tracks is to lower the wait times, and let everyone get a run.
Tiny
Swiss #75
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:11/19/2009 3:56 AMCopy HTML

What kind of speeds have you seen with your engine mods so far?  What rpms will it run in your testing?  Any glitches or problems with the power curve?

Swiss
generatorshovel #76
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:12/26/2009 8:21 AMCopy HTML

Still progressing,,mostly forwards !
I made the new fitting for the bigend feed, but the feeded galled and tried to spin, again
! (luckilly, only while being kicked with ignition off).
Back to 10mm stewies,,fog  it,,it's not a swiss watch,,give it 004" clearance,,and sein' as it grabs way down on the end, chop it off so it only pokes 20mm into crank (hopefully ALL the oil don't squish out 'tween the gap , and not oil the bigend, but the test will see)
I fixed that prob,,and ran it, till it dissapeared into a cloud of SMOKE !,,,I hadn't noticed the (one of 4 lines) oil return from the head was rubbing on the belt,,cutting thru the hose,,and as it was at @ melting temp,,,,it smoked up a bewdy !
Also,,the rocker covers wre gushing oil,,and the temporary clear return lines from the cam return were chockers,,problem,,,,,TOO MUCH OIL TO CAMS,,and not 'nuff return line capacity (4 into 1)
Solution NO1,,drill clutch cover to accept press fit and loctited "water rat" stainless tube,,a plus it they look PURDY.
Start again,,,,methanol pissing outa carb,,,shit in needle and seat,,,,clean,,start again,,,still too much oil to cams,,,,,,solution NO2,,fill fittings feeding into cams with solder,,and drill to 1.5mm (same size as a Honda 125 SOHC feed),,result,,TOO MUCH OIL FEED,,daemmmmmmmmmm !
I dragged oit my trusty 1.25 ltr coke bottle with the tyre valve in the bottom,,and an AN-3 fitting in the lid,,grabbed some more ex ebay AN / npt adaptors and had a brainwave in the process,,,,use some pilit jets from the FZR downdraught carbs, drill and tap fittings to accept 'em,,and pump oil @ 50 psi thru 'em,,bugga,,,drip drip aint enough,,,,,so drilled one to #95 number drill,,,,too much oil,,,drill another to #55,,not 'nuff,,drill again to #75,,,purrrfect (on the + side of purrfect actually,,but concern of minute particles in oil possibly clogging jet,,not good,,so # 75 will do.
I ran it long enough to drink 1 ltr of methanol,,at idle,,wid a few throttle blips,,,,purrrfect with exhaust cam,,,a little too much on intake ? once again,,the test ride will tell me (clear temp return lines)
I'm getting there,,,gotta pull the fittings again,,clean,,and loctite the jets in,,'cos if the fall out,,the cam lube holes will chew 'em up,,and I'll have another '09 failure.

By the way Swiss, your pipe works a treat, power is starting @ 3,000, and strong from 5,000 , right up 'till gearchanges @ 11.000 (according to the XL tach),and it's not offensively loud, many thanks,,again !
Tiny
Swiss #77
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:12/26/2009 4:23 PMCopy HTML

Tiny,

Glad to hear that the pipe is working like I designed it.  If you have any changes that affect the redline/rpm limits, let me know and we can adjust things.  Megaphone systems are slick and can also be adjusted some to work on powerband dips etc...

Swiss
generatorshovel #78
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:01/08/2010 9:18 PMCopy HTML

I think I have to build another workshop ! , it seems, parking a honda close to a HD Panhead allows the Harley's oil leaks to jump ship, , , , ,
For the last 3 weeks I have been trying desperatly to contain the spent oil from the exhaust side overhead gear, Ive lost track of the "O" ring combinations I've used , Iv'e even run 2 X 5/16 ID return lines from the rocker cover, to the clutch cover (ex cover side) and 1 from the inlet cover, in addition to the 2 existing return lines from lower on the head, behind the cam drive belt.
Part of the problem was the oil supply quantity, as @ 50 PS! + the 1mm restrictor as used in the XL's it far too largs, so I've drilled and tapped the AN / 1/8" BSP fittings used to dispense the oil to the cams, and fitted Mikuni pilot jets , and drilled with number drills to #76.
Part of my problem has been christmas, and my isolation, and the inability to buy any 2.76mm "O" ring cord,,,'till today,,hopefully,,some 2.76, and 3mm cord will be here in 3 1/2 hrs, and I might have time to make and fit another "O" ring with a thin film of Loctite master gasket around it before I go to work.
Tomorrow the loctite should have cured,,and I get to fill the shed with castrol "R" laced methanol fumes again,,for oil leak test No 15.
Tiny
Swiss #79
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:01/08/2010 11:50 PMCopy HTML

Good luck with it Tiny!

Swiss
generatorshovel #80
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:01/09/2010 1:19 AMCopy HTML

While I wait for the Loctite 401 to bond, I'll explain the difficult shape of the cover.(the "o" ring cord arrived !)
Because its 1/4 of its former self and the camshafts now exit stage left, thru 3mm aluminium plate which has a seal carrying ring screwed to it (behind camwheel) the "O" ring needs to bend @ 90 degrees to seal between the upright seal carrier section of the head.
Originally (with my engine) an "O" ring was made using 2 x 45 degree cuts, loctite 401'd together where the 90 degree corner was needed,,and it worked fine.
Now with the extra oil present, and the age of the original "O" ring a drip every 5 seconds or so drips from the lower corner, closest the camwheel.
Ive re-filed the cover to try using a one piece "O" ring but the same leak persists, even after JB welding the corners to fit snugly.
I've now gone back to my original idea and re JB'd the cover, and squared up the head's sealing face, hopefully,,it'll work.
I don't have any leaks with the (top) inlet cam cover.
One thing I did notice, in my many hose / no hose combinations, even though I have increased the crancase breather by 300 %, when the engine is run with the dipstick out, the continues to be a LOT of crankcase pressure, and the return flow from the cams is better with the dipstick out, so I've purchased an auto type PCV valve and I'll install it, via a another hose (lol) , fitted into the dipstick access hole.
I only have 'till the end of January to get it sorted, and pay my nomination fee, or its all over for another year .
Tiny
Swiss #81
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:01/09/2010 5:05 PMCopy HTML

Tiny,
I have used car PCV for my XL350 for years.  It always seemed to work well.  Only other solution would be a crankcase evac system that plumbed into the exhaust.  A lot more complicated to build but you could do it if needed.  The thing is that if you are going to PCV one vent you really need to do it for all of the vents.  Otherwise one of the direct vents will just allow more air to flow back into the crankcase.  The whole idea of the PCV is to lower the air density inside the crankcase so that there is less air to build pressure when the piston comes down into the cases.  So any upper cam area vent hose should also go to the same PCV controlled vent tube.  You can do this fairly easily with some of the auto style nylon "T" connectors that they use for combining hoses in the cars.  They use all kinds of size combinations so if you have a large vent hose on your dipstick vent tube and a small hose on a cam tower vent tube you can join them together without a lot of bother.

Swiss
generatorshovel #82
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:01/10/2010 1:00 AMCopy HTML

Thanks for the advice Swiss,,I'll look into that after I solve the oil leak prob,,,yep,,,it's still leaking,,,but not from where I thought,,accidentally, after removing the timing belt, yet again, with the plan of removing the ex cam drive wheel to access an elbow behind it, whicj always looked too shiney for its own good,,,I notices one little drop of golden lube drip from the lower corner of the INTAKE cam cover,,yeah,,the one I was sure was NOT leaking, so after plugging a few oil return lines, and pumping a syringe full of fresh oil into the intake cam chest and waiting,,watching,,behind a 1000 watt floodlight, in the 110 degree shed, I watched the oil drip secretly behind the ex cam wheel, onto the head, and finally, over the seal holder, and dripping from where I thought the leak originated, also , some found its way to the suspect elbow.
Maybe,,I'm close to fixing it,,but now it's time for work again,,,and the next few days will be spent recovering from 2 10 hr nite shifts, by when, ,hopefully, the heat wave will easel, and I'll get into the more important oil leak solving again.
The bonus from todays test run is that I'm a little bit closer to evening up the asshole tally with my young drunk neighbors, having succeded in waking them from the dead long enough for them to slam their bedroom window shut after their all nite doof doof music marathon,,,,,paybacks are fun
Tiny
Swiss #83
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:01/10/2010 4:45 PMCopy HTML

Tiny,

What city/town are you located in?

Swiss
generatorshovel #84
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:01/10/2010 9:50 PMCopy HTML

Broken Hill NSW (as west in NSW as it gets)
Tiny
PS. the intake rocker cover "O" ring is a sorry excuse for an "O" ring, no wonder it leaks
generatorshovel #85
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:01/14/2010 1:14 AMCopy HTML

NO MORE OIL LEAKS ! 

It's sounding SWEET too, next task,,,test ride 
Tiny
Swiss #86
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:DOHC 161cc LSR project update

Date Posted:01/14/2010 2:04 AMCopy HTML

Way to go Tiny!!! 


Swiss
generatorshovel #87
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:01/17/2010 10:57 PMCopy HTML

Test runs completed today, and it STILL GOES !
Thats a bonus,,,,,,,,
Tiny
OZ_Sparklz #88
  • Rank:Diamond Member
  • Posts:1717
  • From:Australia

Re:DOHC 161cc LSR project update

Date Posted:01/23/2010 10:08 AMCopy HTML

Loving the tales Tiny, keep 'em coming!
generatorshovel #89
  • Rank:Gold Member
  • Posts:152
  • From:Unknown

Re:DOHC 161cc LSR project update

Date Posted:01/27/2010 10:44 AMCopy HTML

That's it for my updates 'till I get back from Lake Gairdner mid march, hopefully, with some good news
Tiny
OZ_Sparklz #90
  • Rank:Diamond Member
  • Posts:1717
  • From:Australia

Re:DOHC 161cc LSR project update

Date Posted:01/28/2010 1:57 PMCopy HTML

Good luck Tiny, we are all pulling for you to run fast, safe and without problems Mate!!


Go soothingly on the grease mud ... as there lies the skid demon! ...





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