Fig Jam 477cc ;)

Dool

Dool

Backyard Bodger
Staff member
Distributor
Developer
477 Owner
Stock bike on this Dyno is 22RWHP

Add the Big Bore Kit with the Red Box 👹 a Pod Filter and a cheap muffler and you get 26.5RWHP a bit over 20% see map dated 15/11/22.

Add to that a better exhaust system and the Headline figure improves by 1.4% although looking at the second chart of today's run you will see 2+ RWHP separating the lines from 5400rpm to 7000 ( and beyond:rolleyes: ). 27.9RWHP .

A full 27% increase in usable Real Seat of Pants Power.

All this with a Stock Head and Cam ! , best chart I've seen is 31 RWHP with a larger Throttle Body and a Tec Cam and some Port and Valve work ( same Exhaust) using a Mk1 piston so perhaps the next run will include something like that , more compression, HT Cam, 40mm throttle body! or maybe 36mm:unsure: ( but not a Mk1 Pistono_O )

This work has been done with a minimum of Tools, nothing special except a Bike Bench;), single handed so to speak ( alone ) and even half witted at times:LOL:

Okay First Chart ( stolen off the net) shows HP ! at the Crank so from a Base of 24.5 BHP another 4.9 is added with a good exhaust and a Cam.

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direction!
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So after that Ego massage I put the Bike up on the Bench and changed Cams, HT-b of course just applying the first round of 10Nm tension to the Cam Cover Bolts and the least important of the 6 main bolts stripped:confused:, no big drama but it wasn't the end of the day I had envisioned.

Head does not need to come off for this repair but I will take the opportunity to remove it and the Piston/Barrel both of which are being gifted to separate but equally deserving 477 Mk1 owners.

@RCruiser has a Mate who wants the Piston and an Aussie get the Barrel ;) , hes not on here!

My Thanks to @Sasa for the Map Development and Software Training supplied selflessly, I am certain we would get 2 to 3 more HP with a Cam but I have proven that before with the first 477.

Now I think I will use the Silly Season to work on my Wheelie Machine, 500cc , 40mm Throttle Body, Ported BV Head and a "BrisK" spark Plug:LOL:
 
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Off with the Head, drilled., tapped to 8mm and SS steel thread insert fitted.
The "L" plate is fitting as I am not a Machinists shadow.
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Initially I wanted to leave the Head on so I drilled in situ to ensure I was not "off course". I had thought to Tap the thread and install the Heli-Coil with the Cover on But the Shank of the Tap was larger than the thread and would not pass thru the Cam Cover
All was going well until the Heli-coil jumped a thread and I then decided to do a Proper job!
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Heli-Coil on the Top , Sert on the Bottom, this is Head number 5 out of 6 and has already lost 2 threads!
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Both Hold 14 Nm and its back together and running, of course ;) test ride tomorrow , dyno in 8 days
 
This could make an interesting Chart, I did not feel any difference until 5000rpm :unsure: 7 days to go.
 
Finally have the Piston Vice sorted, now I can adjust the compression ;)
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I wish I had a mill to do these games myself!

I might source a lathe before summer, but I'll be still dreaming of a mill!
 
Milling Machine was sort of a Mistake!, Had I seen it before I would not have bought such a Big one, getting onto my Ute was difficult with an overhead crane and getting it to the back of my House a Challenge without a Crane. It will not be going anywhere soon!
Lathe is too small but could be set up on the Milling machine Table.
Great if you know how to use them, I am just learning.
 
It took me a while but I figured out how to do it, rotated the piston vice 90deg and it enables me to use the table stop, speeds things up!
Dremel is quicker but this is down to 0.02mm accuracy so cant argue with that!
2 cuts and only 6 to go!
 

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Remember the Story about the Haire and the Tortoise?
Well this is a Turtle! no comparison :cool:
 

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Head has been "Treated" to a birthday or something, combustion Chamber increased in volume to 38cc, larger Valves and Ports and a full set of Cam thread Inserts, well the 6 across the Cam :rolleyes:
Compression Ratio almost 11 to 1 I calculated on this Piston.
 

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Dool said:
Head has been "Treated" to a birthday or something, combustion Chamber increased in volume to 38cc, larger Valves and Ports and a full set of Cam thread Inserts, well the 6 across the Cam :rolleyes:
Compression Ratio almost 11 to 1 I calculated on this Piston.
Click to expand...
What was the volume before your treatment?

With 38cc of combustion chamber and a flat piston the compression ratio should be close to 13.5:1, or am I missing something?

Shouldn't you calculate (38+477):(38) = 13.5:1?
 
34cc before, Comp ratio as calculated should come to 11 to 1, I am unfamiliar with your calculations
My Cast pistons may not be too good at 13.5 to 1.
Anyhow we shall see when it fires up, if it does!
 
I finished my real job early and had a chance to get into it, Installed the OEM Cam and used new RE 60mm bolts on all the Cam tunnel except one which needs to be 65 but is currently 70 and a SHCS ( Titanium ones ordered ) nice Sharp click when the Tension Wrench goes off at 15 NM;)
A Static compression Test prior to start up looks low but I am confident.
A video of this test was posted on you tube so I could share it with @Sasa , Turtle power :unsure:
 

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Start up this morning, it sounded like the exhaust had a hole in it and would not Idle, I had to raise the Idle ( and the Petrol Tank !) significantly then give it 10% more fuel in the range for an Idle.
Runs quieter than a Swiss watch, in the Suburbs it was smooth but on the Hwy when I gave it a handful it initially hesitated.

My take is that it needs more Fuel so I will load more across the board and check again tomorrow.

 
A first for me today , I stopped at a Fuel station and topped up with 91Ron unleaded, I intend to run this on the cheaper option.
Let it cool down after the ride and took its Pulse again;) up a bit as the Valves found their place, check Tappets again Monday:(



Nearly 30psi ! Valves were not Lapped nor Ground into the Seats, I rely on interference angle, prior to fitting the head I could see light in the Exhaust Port, not much! but it was there:)
 
So just in case tomorrows dyno doesent go the way I Dreamed here is the disclaimer,


Excuse 1, Piston is too new, yeah just put it in a couple of days back with the old rings and pin into the "other" cylinder so I should have given it more time.

No 2, My Piston is crap because real pistons dont have fkn turtles on them, I did wonder about that!

No 3, The Valves protrude into the Combustion Chamber and look Dorky, ahh well it a "look" thing!

No 4, @Sasa gave me the wrong Map ! I would have never guessed ;)

One thing is for sure is $100 will exit my wallet:rolleyes:

Last Run Before the Silly Season and the New Year.🎅
 
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