Motorrads Jeff Ward engine build series 3

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Sandblaster
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

Motorrad

Top ring end gap. .014"
Botton ring end gap. .0155

on the money for a 90mm motor

evil

now if I could just find where I put the wrist pin. angry

Thanks to blaster for the measurement I needed of unmolested parts
KX500 JEFF WARD ROUND 3 REBUILD 1085.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1085.jpg (173.69 KiB) Viewed 9659 times
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Sandblaster
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

Motorrad

jug is on. so I can now measure deck. to fine tune my head CC's to hit the compression ratio I want.

.048" positive deck hight.

Formula For Milling PistonsTop per lunati
(For 4032 material only)


Piston dome cc's to gram conversion: 1cc (volume) = 2.8 grams (weight)

This is a good way to remove excess dome without having to re-cc piston: Mill a small amount and re-weight piston until total reduction is reached.

Example:

A piston has 12.5cc effective dome volume. The desired effective dome volume is 10.5cc.

To remove 2.0cc, cut 5.6 grams (2 X 2.Cool from the piston dome.

sandblaster

It's gonna depend on the alloy content of the aluminum used.
Good luck finding that.
Since you know that, I can only assume that this is another test to keep me endlessly searching the internet for trivia that can't be found.
Darn you Motorrad!
So I suspect that the difference between your calculations using 4032 and the cast aluminum will be so slight as to be difficult to measure.
Then again I don't weigh things by their sub atomic densities.... very often

Motorrad

Perhaps you should start

Other head had been cut too much to get it up to the needed chamber cc

So

Started with a new head

And fresh off the lathe from being molested
KX500 JEFF WARD ROUND 3 REBUILD 1086.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1086.jpg (167.36 KiB) Viewed 9659 times
sandblaster

Looks sweet as always....
Is that Dawn soap?

Motorrad

Yup. Best thing to happen to cylinder's and heads ever.
If bikes are for kids I'll never grow up.
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Sandblaster
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

Motorrad

Missed my cc's a bit. So here we are making some cc adjustments. Now we are within 1/4 of a cc. Close enough for me
KX500 JEFF WARD ROUND 3 REBUILD 1087.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1087.jpg (289.47 KiB) Viewed 9648 times
Head hand lapped to perfection. And very smooth gasket surface.

Trip through ultrasonic cleaner to get any compound from polishing or lapping off.
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Sandblaster
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

KX500 JEFF WARD ROUND 3 REBUILD 1088.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1088.jpg (208.93 KiB) Viewed 9648 times
Had to take .037" off of dowel pin as to bit bottom out

Say by by
KX500 JEFF WARD ROUND 3 REBUILD 1089.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1089.jpg (207.16 KiB) Viewed 9648 times
Magic custom gaskets. And checking squish clearance with the dial indicator.
KX500 JEFF WARD ROUND 3 REBUILD 1090.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1090.jpg (194.35 KiB) Viewed 9648 times
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Sandblaster
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

Motorrad

.04725" squish clearance. If anyone besides blaster cares

81cr450

.04725 ? due to the cc recalc or on purpose, always thought .037 was the G spot. Care to quantify

just curious, if theres a practicality behind it, i have the 87 head thats already near .100 in the hole

16
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Sandblaster
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

demographic
KX500 JEFF WARD ROUND 3 REBUILD 1091.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1091.jpg (188.33 KiB) Viewed 9647 times
Looking through this thread and unless I've missed it (its possible but I think I've had a good look through the thread) there doesn't seem to be much mention of the fact that the cylinder on the right (the Jeff Ward one) has one single window on each side of the main exhaust port instead of the two each side like the standard one.
Now if I remember right those ports go to the powervalve's and the Jeff Ward jug has basically removed the bridge between those powervalve ports and squared the holes up.

In this picture they are labled PV and the measurements are only measured off the paper top and not absolutely exact so don't trust them too much.
KX500 JEFF WARD ROUND 3 REBUILD 1092.jpg
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

sandblaster

And a few other mods as well :D

Motorrad

That work wasn't done by team green.

There is A LOT of work done in that area if you know what to look for :ugeek:

timing set
KX500 JEFF WARD ROUND 3 REBUILD 1093.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1093.jpg (188.77 KiB) Viewed 9647 times
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

Motorrad
KX500 JEFF WARD ROUND 3 REBUILD 1094.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1094.jpg (180.25 KiB) Viewed 9647 times
Installing team green radiators after fabricating all the custom mounts again since I lost the others
KX500 JEFF WARD ROUND 3 REBUILD 1095.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1095.jpg (118.35 KiB) Viewed 9647 times
KX500 JEFF WARD ROUND 3 REBUILD 1096.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1096.jpg (145.91 KiB) Viewed 9647 times
KX500 JEFF WARD ROUND 3 REBUILD 1097.jpg
KX500 JEFF WARD ROUND 3 REBUILD 1097.jpg (132.89 KiB) Viewed 9647 times
KX500 JEFF WARD ROUND 3 REBUILD 1098.jpg
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Sandblaster
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

Motorrad

Rads fitted.
they are 3 row. (stock is 2) and large capacity ontop of that.

Measured my coolant going in.

I have 25% more capacity than stock. (ontop of being 3 row)...


If the large impeller works out. with the other cooling system mods.

As Sandblaster put it.

My bike will be "pooping ice cubes out the pipe"
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Sandblaster
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Re: Motorrads Jeff Ward engine build series 3

Post by Sandblaster »

Motorrad

Two heat cycles in and all is well

Three heat cycles down and all is well.
If bikes are for kids I'll never grow up.
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