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JMH's 1060 Big Bore project

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dog78 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote dog78 Quote  Post ReplyReply Direct Link To This Post Posted: 12 Nov 2017 at 14:07
Hi, Gabro had a set of cams ( welded ones) with a long duration, I think he wanted €300 for them, he offered them to me, but I had already acquired the one piece cams by then. He may still have them and all inlets. Instead of the power finishing at 9.6k it will finish at 10.4 which is quite an improvement. But this may affect your piston to valve clearances.
Gabro is an absolute gentleman, very helpfull and knowledgeable always exploring new ideas like Micah. Them cams just a thought, I think they have been modified too, I think the duration of an inlet cam is about 270 degrees and the one he offered me might have had a bit more.
What valve timing are you going to run?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JMH Quote  Post ReplyReply Direct Link To This Post Posted: 12 Nov 2017 at 19:08
No sure about the timing. I do not need excessive midrange to make it unrideable so maybe 110/114 or something like that.
 
Mille Aarrr -02
My riding lines are like Hendrix's solos. Unexpected and always different.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JMH Quote  Post ReplyReply Direct Link To This Post Posted: 12 Nov 2017 at 19:09
A bit daft question. I've read about these 51->57 TB conversions and how you need to put the cold start mechanism to the newer and larger TB. When I looked at my old one and future one the only thing I needed to take from the old was the intake pressure sensor as the new one did not have this plugged. There is even a place for the idle tuning knob. You just screw it in place.

Do I have this right now:

57 mm to the right.
As I will have the TSS slipper I do not use the vacuum lines. The newer one has some extra tubes, which went to the airbox if I remember correctly. I just plug all the four holes marked with red:


57 mm on the right
Red dots for throttle cables, blue dot for the cold start cable and the green dot accepts the idle adjuster knob. (the one from the old one was bent so I'll use the one still in the bike. I have many TBs)


So, the immense work was to clean the old TB and get the intake pressure sensor (green dot) out and connect it to the lines marked with red dots.


I also checked the adapters for the jets I got from Raimo from Sweden. They are all good. I can get the PCII plugged to the new larger TB.
Mille Aarrr -02
My riding lines are like Hendrix's solos. Unexpected and always different.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JMH Quote  Post ReplyReply Direct Link To This Post Posted: 13 Nov 2017 at 07:04
I found out that early 2004 TBs can be like that.
Mille Aarrr -02
My riding lines are like Hendrix's solos. Unexpected and always different.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JMH Quote  Post ReplyReply Direct Link To This Post Posted: 21 Nov 2017 at 19:05
Last weekend we made some layer cakes. Bottom with a“new” cylinder, mid 04 Gen2 head and on top my good old valve cover.



One mistake was observed though. We had the M5 threads done to the cam supportbut missed the fact that the sensor support has short 7 mm diameter guidance sleeves, or whatever. So, we will have that redone.


The heads were checked for straightness and sealing and they were OK. No porting was done after all and we also decided not to TIG weld the cam lobes to the shafts as the cams are standard as well as the valve springs.


The machined front head:



The sensor support



And these holes need some regrinding



The camsprockets were also machined to enable adjustment.

These goodies went in



We put the pistons in from the top and checked that there is just enough space to put the piston pin in place from under without taking the piston too far out.
The piston fiddling was a patient man’s game as the three-piece lowest oil ring was tricky. But we got there eventually. The top compression rings were quite easy. All was done by hand with a small screwdriver as the tool.

The manual says to place the piston ring gaps with 120 degree spacing. This did not satisfy my mate and he checked what the samurais would do (Yamaha). So, we ended up the two gaps of the lowest oil ring with roughly a 90 degree spacing on the exhaust side and the top compression rings with a ~90 degree spacing on the intake side. I cannot remember where we put the lowest oil ring spacer ring gap. Somewhere probably.


The crank and balancer bushings have arrived so by end of next week they will be in their place. The diameter of the bores will be measured as well as the crank diameter.
The clutch and gearbox are on their way and hopefully are in time so that we can start to put the engine together end of next week.
Mille Aarrr -02
My riding lines are like Hendrix's solos. Unexpected and always different.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JMH Quote  Post ReplyReply Direct Link To This Post Posted: 22 Nov 2017 at 07:45
A have a question about clutch springs. What to use with the TSS slipper and increased power?
 
Old OEM ones
EBC 10% stiffer
Barnett heavy duty ones
 
Any experience?
Mille Aarrr -02
My riding lines are like Hendrix's solos. Unexpected and always different.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Paddedcell100 Quote  Post ReplyReply Direct Link To This Post Posted: 22 Nov 2017 at 08:57
Originally posted by JMH JMH wrote:


A have a question about clutch springs. What to use with the TSS slipper and increased power?
 
Old OEM ones
EBC 10% stiffer
Barnett heavy duty ones
 
Any experience?


I picked my bike up from AP a few weeks ago after having a 1060 build and a TSS and Surflex fitted, I asked them to stick a set of heavy duty Barnett springs in mine (as recommended by Hemi, as that was the same set up he's got in his 1103).
It's only a few weeks old but all good so far, finding neutral is a bit of a game still but you can usually get it as you are rolling to a stop with a couple of up and downs and I'd rather have a clutch that can take the power than one that finds neutral easily.
Better to have something you don't need than need something you don't have....
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JMH Quote  Post ReplyReply Direct Link To This Post Posted: 22 Nov 2017 at 10:17
OK.
 
Might need to add the springs to the list at least.
Mille Aarrr -02
My riding lines are like Hendrix's solos. Unexpected and always different.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JMH Quote  Post ReplyReply Direct Link To This Post Posted: 22 Nov 2017 at 11:53
Maybe I'll go with the old standard friction plates and old standard roughened steel plates together with 10% stiffer EBC springs and the higher preload the kit offers.
 
Springs are only 13 €.
Mille Aarrr -02
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Paddedcell100 Quote  Post ReplyReply Direct Link To This Post Posted: 22 Nov 2017 at 15:44
Originally posted by JMH JMH wrote:


Maybe I'll go with the old standard friction plates and old standard roughened steel plates together with 10% stiffer EBC springs and the higher preload the kit offers.
 
Springs are only 13 €.


I think the struggle to find neutral aspect is a signature thing with the Surflex clutch pack , on these bikes anyway.

its a bit of a pain but unless you were going to use it for commuting or doing a lot of town/city miles(on a 1060 kitted bike? )then it's something im.happy to live with for a clutch that's up to the job of handling the extra power.
I only went for a Surflex after asking Hemi what he used and him telling me that a Barnett clutch soon started slipping after his 1103 build, so that's the way I decided to go as well, I think AP use an EBC clutch combined with Barnett springs normally mind you🤔
Better to have something you don't need than need something you don't have....
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JMH Quote  Post ReplyReply Direct Link To This Post Posted: 22 Nov 2017 at 15:53
I'll measure the stack on the used ones first as per RSV manual before deciding on new plates. If within spec I'll stick to them. If not, maybe new EBC plates. We'll see. At least the springs are on order.
Mille Aarrr -02
My riding lines are like Hendrix's solos. Unexpected and always different.
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