Let the BIG BORE build begin!
Outstanding HDF Member
Joined: May 2008
Posts: 2,543
Likes: 19
From: Ashland Ohio
You will need those CRs when it's hot down there! 207ccp! Whew!
Good Luck, THIS is the fun stuff.
This far apart? For piece of mind... check pinion run out.
I sent you a PM, but never mind... I thought that YOU were doing this upgrade.
Good Luck, THIS is the fun stuff.
This far apart? For piece of mind... check pinion run out.
I sent you a PM, but never mind... I thought that YOU were doing this upgrade.
Last edited by wurk_truk; Sep 28, 2009 at 11:08 PM.
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Ultimate HDF Member
Joined: Dec 2006
Posts: 8,294
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From: Po-Dunk Looziana
Bob, the decision to do this was a last minute thing. I was/am nervous about all this. I don't like seeing my bike in a bazillion pieces. My main concern is the potential for more noise.........ie, top end noise. I like a smooth running engine without adventitious sounds!!
Extreme HDF Member
Joined: Sep 2005
Posts: 11,615
Likes: 50
From: Baton Rouge, LA
Bob, the decision to do this was a last minute thing. I was/am nervous about all this. I don't like seeing my bike in a bazillion pieces. My main concern is the potential for more noise.........ie, top end noise. I like a smooth running engine without adventitious sounds!!
After seeing the dyno chart on that other thread I think this is a great bang-for-the-buck option for you with your connections with the dealer. Keep us posted on the project!
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Ultimate HDF Member
Joined: Dec 2006
Posts: 8,294
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From: Po-Dunk Looziana
Well, we began rebuild yesterday afternoon around 2PM CST and finished around 9PM CST.
Took our time and torqued every single bolt to spec. Attention was paid to machined surfaces and much care was taken to prep these surfaces for proper seal.
All new gaskets and o-rings from base to top of rocker boxes were placed, lines and hoses secured and chrome polished.
I'll apologize in advance for the lack of pics throughout the assembling process, I was waaaaaaaaaay to nervous for that and was ready to get things back together so I can sleep at night. LOL!
The build consists of the 1690 SE Flat top Cast pistons, my own cylinders bored to 3.875", 0.030 Cometic head gasket(way cool BTW!!), Jims manual compression releases, SE255 cams, new lifters, new stock pushrods, SERT tuner, new o-rings and gaskets, oil, and a whole lot of prayers and sleepless nights!!!!!
The bike FIRED right up, no top end noise, and it sounds wicked good!!!
My final numbers are estimated at 10.01:1 static compression, (9.7:1corrected) and 203.8 cold cranking compression.
I hope to get some time on it soon but we are having TORRENTIAL rains right now
WTF?!?!?!?!?!?!?!?!
Few pics of the finished product.
COMPRESSION RELEASES:
Ed, if you are reading this hopefully sometimes at the end of next week we can get this thing tuned!!!!
Took our time and torqued every single bolt to spec. Attention was paid to machined surfaces and much care was taken to prep these surfaces for proper seal.
All new gaskets and o-rings from base to top of rocker boxes were placed, lines and hoses secured and chrome polished.
I'll apologize in advance for the lack of pics throughout the assembling process, I was waaaaaaaaaay to nervous for that and was ready to get things back together so I can sleep at night. LOL!
The build consists of the 1690 SE Flat top Cast pistons, my own cylinders bored to 3.875", 0.030 Cometic head gasket(way cool BTW!!), Jims manual compression releases, SE255 cams, new lifters, new stock pushrods, SERT tuner, new o-rings and gaskets, oil, and a whole lot of prayers and sleepless nights!!!!!
The bike FIRED right up, no top end noise, and it sounds wicked good!!!
My final numbers are estimated at 10.01:1 static compression, (9.7:1corrected) and 203.8 cold cranking compression.
I hope to get some time on it soon but we are having TORRENTIAL rains right now
WTF?!?!?!?!?!?!?!?!Few pics of the finished product.
COMPRESSION RELEASES:
Ed, if you are reading this hopefully sometimes at the end of next week we can get this thing tuned!!!!
Last edited by UltraKla$$ic; Oct 4, 2009 at 11:36 AM.
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Ultimate HDF Member
Joined: Dec 2006
Posts: 8,294
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From: Po-Dunk Looziana
Freight train!!!! WOOT!!
Just finished riding it and "seating the rings" with the 30-60mph x10 3rd gear pulls and this thing pulls like a freight train!! 
I'm stoked!
Thanks to ALL that contributed behind the scenes! I owe yall BIG TIME!!!!
I'm stoked!Thanks to ALL that contributed behind the scenes! I owe yall BIG TIME!!!!
Last edited by UltraKla$$ic; Oct 5, 2009 at 10:40 AM.
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Joined: Jul 2007
Posts: 2,196
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From: Shenandoah, TX
Hey Darren great job and great right up also. You want be sorry. You'll also never be satisfied with another stock scoot, trust me, I've cursed myself for life.
On another note. The compression release valves you install, was that just a precausion, or do you realy need them? I have 9.7-1 and don't need them as of yet anyway. My battery is new and still hot. Just asking
On another note. The compression release valves you install, was that just a precausion, or do you realy need them? I have 9.7-1 and don't need them as of yet anyway. My battery is new and still hot. Just asking
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Ultimate HDF Member
Joined: Dec 2006
Posts: 8,294
Likes: 33
From: Po-Dunk Looziana
Hey Darren great job and great right up also. You want be sorry. You'll also never be satisfied with another stock scoot, trust me, I've cursed myself for life.
On another note. The compression release valves you install, was that just a precausion, or do you realy need them? I have 9.7-1 and don't need them as of yet anyway. My battery is new and still hot. Just asking
On another note. The compression release valves you install, was that just a precausion, or do you realy need them? I have 9.7-1 and don't need them as of yet anyway. My battery is new and still hot. Just asking
Regarding the compression releases, I did it since I had access to the tool and the heads were in my hands. Our lead mechanic has a 103/255 build and he gets frequent hot starts and he had to tear the heads back off and put ACR's in his. I chose manual releases for less failure rate over the ACR's but those little suckers are hot after riding for a distance....LOL!
Can't wait till the weather clears up here so I can put more miles on. Then it's dynotune time!
Outstanding HDF Member
Joined: May 2008
Posts: 2,543
Likes: 19
From: Ashland Ohio
GREAT! Absolutely great news!
I just passed the 1000 mark on my build.
I have about 185 ccp on a 106. Starts pretty easy. You did the right thing installing the CRs. So little time and effort when it's all apart, and if you never need them, who cares. Running higher compression with those 255s... and their 25 degree close... it's just smart insurance. My cams have a 42 close. I didn't really think that I would need them, but... it was apart and $100 for the releases and the machining??? Couldn't pass it up.
Small manual CRs are the way to go. ACRs are a pain and can be problematic.
Again, congrats on the build. It IS way funner than installing pieces of chrome, isn't it? HAHA!
Get a compression gauge. At 500 miles check you CCP. Cold Cranking Pressure. That way, at any time in the future you think you have a problem, you can mentally refer back to this number. Also, it's a good check up on your work. I was nervous when I did my 500 mile CCP. HAHA!!!
You did GOOD!
I just passed the 1000 mark on my build.
I have about 185 ccp on a 106. Starts pretty easy. You did the right thing installing the CRs. So little time and effort when it's all apart, and if you never need them, who cares. Running higher compression with those 255s... and their 25 degree close... it's just smart insurance. My cams have a 42 close. I didn't really think that I would need them, but... it was apart and $100 for the releases and the machining??? Couldn't pass it up.
Small manual CRs are the way to go. ACRs are a pain and can be problematic.
Again, congrats on the build. It IS way funner than installing pieces of chrome, isn't it? HAHA!
Get a compression gauge. At 500 miles check you CCP. Cold Cranking Pressure. That way, at any time in the future you think you have a problem, you can mentally refer back to this number. Also, it's a good check up on your work. I was nervous when I did my 500 mile CCP. HAHA!!!
You did GOOD!
Last edited by wurk_truk; Oct 4, 2009 at 05:00 PM. Reason: stoopid, dumb, and mentally deficient