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 Post subject: Re: CA Pilot CSI-
PostPosted: Sun Feb 19, 2012 10:50 pm 
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Joined: Mon Jul 19, 2010 3:20 pm
Posts: 1266
Location: saskatoon, sk, canada
not sure about the pilots but the 350s have a green wire in the steering column that was meant for the tach, you could look for it not the pilot, and try it


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 Post subject: Re: CA Pilot CSI-
PostPosted: Mon Feb 20, 2012 8:03 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
I hooked the green wire to the black/yellow pulse wire on the coil side. I have the internal combustion Engine apart currently but will keep you informed.


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Feb 25, 2012 5:42 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22129
Location: Chicago
viewtopic.php?f=4&t=6158&p=52620

Check your PM murray


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Feb 25, 2012 7:29 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
download/file.php?id=21207

thanks Hoser


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Feb 25, 2012 9:25 pm 
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Joined: Sat Mar 26, 2011 5:47 pm
Posts: 68
Not being a smart ass, just wondering why you need a tach when you don't have to ever shift and there is a built in rev limiter? For the "BLING" factor?


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Feb 25, 2012 9:56 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
No question too stupid, I primarily use the tach for clutch tuning. I can see stall speeds between spring settings especially with a 102c clutch. In my Powerblocs, the amount of pucks I take in and out of the clutch really is assisted by reading the tach. Again this is just my way of tuning my clutches. Bling really has nothing to do with it for me. I have 4 trailer queens with bling bling bling! :-)


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 Post subject: Re: CA Pilot CSI-
PostPosted: Fri Mar 02, 2012 9:31 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
Hoser has received the used cylinder and piston. A quick CSI before boring would be cool. Just to see if I was correct on my initial diagnosis. Does not hurt to get a professional opinion!


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sun Mar 04, 2012 10:28 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
I am going to switch the exhaust from a Rev Pipe to a Paul Turner full exhaust with a Fat Boy silencer. I have 1 of these exhausts on my NY Pilot and I love the sound and the pipe to me matches well for my riding. I noticed the Paul Turner gives me better mid range tuning so it is going onto this Pilot. I completely stripped and sanded the pipe down to bare metal yesterday and welded the old EGT hole in the throat as I do not run them. Today I will prep and paint the expansion chamber with a high heat flat black paint.
I also love the way the FAT BOY silencers mount on a Pilot, they give you a ton of room for access and they just mount a ton easier then the ATVR systems in my opinion.Also food for thought you can mount a spark arrestor on these pipes in minues for STATE PARK riding or locations that require decibel levels where a ATVR pipe does not afford this.


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 1:08 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
Got a fresh re sleeved jug back in here last night and started to assemble the motor (( Internal Combustion Engine ? )) again.
I first checked the tech pages for piston prep and performed them as per Hoser's tech page.
After sanding with 440 wet/dry paper all the surfaces that could scrap oil off the cylinder wall, I washed the piston n warm soapy water and use a hair dryer to dry it.
I then went ahead and started the process of measuring the ring gaps,piston to wall clearances.
Ring gap was .012 or 0.30mm. Standard for a 3" bore from Wiseco is .012.
Piston to wall clearances are as follows:
TDC (Top Dead Center) measuring about an inch below- .006 or 015mm
BDC measured at the base if the cylinder skirts-.003 or 0.08mm

Is that piston wall clearance to tight? I thought I had read a min of .004 was best suited for our engines?


Attachments:
File comment: 80mm Wiseco
CA pilot engine specs 001.jpg
CA pilot engine specs 001.jpg [ 29.34 KiB | Viewed 833 times ]
File comment: lightly sanded the surfaces
CA pilot engine specs 002.jpg
CA pilot engine specs 002.jpg [ 53.12 KiB | Viewed 833 times ]
CA pilot engine specs 003.jpg
CA pilot engine specs 003.jpg [ 34.92 KiB | Viewed 833 times ]
CA pilot engine specs 006.jpg
CA pilot engine specs 006.jpg [ 43.57 KiB | Viewed 833 times ]
File comment: piston to wall clearance
CA pilot engine specs 007.jpg
CA pilot engine specs 007.jpg [ 41.8 KiB | Viewed 833 times ]
File comment: again piston to wall clearances
CA pilot engine specs 008.jpg
CA pilot engine specs 008.jpg [ 42.59 KiB | Viewed 833 times ]
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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 1:13 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22129
Location: Chicago
"piston to cylinder clearance" is measured at the LARGEST part of the piston you can find.

Pistons are cam ground meaning they are oval and NOT round.

Pistons are also tapered they are SMALLER at the top than at the bottom.


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 1:43 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
Largest part on the overall piston Hoser?
I re measured the piston and bore using calipers but will recheck the overall size of the piston.
I had measured the piston and such as per:

viewtopic.php?f=1&t=3115" .".." ."..

Using this method but measuring at the top of the bore/piston and the bottom of the jug before the skirts I got the following:
top of piston/bore
cylinder 79.95
piston 79.74
that gives you 0.21 inches or .007mm clearance

bottom of piston/cylinder
cylinder 80.04
piston 79.91
that gives you 0.13 inches or .005mm clearances.

Soemthing does not seem right here. I am glad I checked them. I will know do as Hoser mentioned and check for the largest measurment on cylinder and piston and mark them as well.


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 2:17 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
Tools used for measuring bore/piston.
Piston box for records as well.


Attachments:
CA pilot new piston 002.jpg
CA pilot new piston 002.jpg [ 48.85 KiB | Viewed 829 times ]
CA pilot new piston 003.jpg
CA pilot new piston 003.jpg [ 44.77 KiB | Viewed 829 times ]
CA pilot new piston 001.jpg
CA pilot new piston 001.jpg [ 50.28 KiB | Viewed 829 times ]
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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 2:20 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
re measured using my calipers-

3.161 greatest width on cylinder
3.149 greatest width piston
that gives me 0.012 inches wall clearance which is way high.

More to come as I figure this out.


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 2:22 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22129
Location: Chicago
You need something like this to measure the bore ID not those things your currently using

Image

Acceptable methods found here viewtopic.php?f=1&t=3115
read carefully.


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 3:01 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
OK.
Read that thread on piston to wall clearances and figured out what I did wrong measuring.
Now- Largest size on piston was 3.146 inches
Smallest size on bore was 3.142 inches
This makes the piston to wall clearance at 0.004 inches perfect.
Thanks for the help in the chatroom today Hoser!!


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 4:19 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
Top end installed. Reed cage installed. Going to check squish with Speedchaser head installed. Wit overnight and leak down test in the AM.i PURCHASED A NEW 39mm PWK carb for this rebuild as well.Need solder, ran out. Heading over to Home Depot for some and will post results.


Attachments:
ca motor pictures 001.jpg
ca motor pictures 001.jpg [ 54.74 KiB | Viewed 813 times ]
File comment: As per Hosers tech, added a little bead here for some extra help.
ca motor pictures 002.jpg
ca motor pictures 002.jpg [ 49.57 KiB | Viewed 813 times ]
ca motor pictures 003.jpg
ca motor pictures 003.jpg [ 64.29 KiB | Viewed 813 times ]
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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 5:55 pm 
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Joined: Thu Nov 27, 2008 1:45 pm
Posts: 835
Location: Cedar Crest New Mexico
Mudbogger wrote:
Thanks for the help in the chatroom today Hoser!!


How do you go in to the chatroom, I have never been able to get in there.


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 8:13 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
Squish measured tonight.It varied from clutch side to mag side. Clutch side was 0.052 inch. Mag side was 0.054 inch. If I understand this correctly the variance is due to the piston crown being uneven from the manufacturer.Is this squish good to go? I am using a Wiseco head gasket not OEM. Head torqued as per manual specs.I used .065 thickness solder and measured it from this thread:

http://www.pilotodyssey.com/Squish_What ... eck_it.htm


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sat Mar 17, 2012 8:14 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
scpilot66 wrote:
Mudbogger wrote:
Thanks for the help in the chatroom today Hoser!!


How do you go in to the chatroom, I have never been able to get in there.


Steve go to the main page and download the chatroom off the MIRC link. It tells you how to get there step by step.


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sun Mar 18, 2012 7:23 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
Performed air leak down test on Engine today. Clutch side crank seal leaking ever so slightly. Otherwise it looked fine, bottom end had no leaks.
This is with 8 psi in the motor (( Internal Combustion Engine ? )).


Attachments:
clutch seal 001.jpg
clutch seal 001.jpg [ 58.95 KiB | Viewed 793 times ]
clutch seal 003.jpg
clutch seal 003.jpg [ 56.7 KiB | Viewed 793 times ]
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 Post subject: Re: CA Pilot CSI-
PostPosted: Sun Mar 18, 2012 7:35 pm 
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Joined: Sun Jan 09, 2011 5:33 pm
Posts: 319
Location: Cincinnati, Ohio
That can be replaced without taking the bottom end apart cant it?


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sun Mar 18, 2012 7:59 pm 
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Joined: Mon Oct 25, 2004 10:02 am
Posts: 2208
Location: East Peoria IL
Do you need to replace?


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sun Mar 18, 2012 8:02 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22129
Location: Chicago
viewtopic.php?f=25&t=5597


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 Post subject: Re: CA Pilot CSI-
PostPosted: Sun Mar 18, 2012 8:44 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
I did replace the seal yes. And it still leaked again. I had the seal flush against the cases so I tapped it further on the shaft-did not help. I took the new seal out and again cleaned the crank end with nail file from my wife(not very coarse at all) and scotch pad AGAIN BEING SURE NOT to let debris fall into the cases. Will update you here.I did get some more debris off the crank end this second time. I have never had a clutch side seal leak on me, I assume this seal should seal properly after I clean and prep this again here.

AND IT DID !!! sealed right up. The key item was to install new seal flush with cases and make sure the crank end is 100% clean. Air leak tested again and the exhaust flange gasket is leaking so I cleaned that up and re installed it. Will let it sit overnight and test it tomorrow after work.


Attachments:
crank seal CA pILOT 001.jpg
crank seal CA pILOT 001.jpg [ 36.47 KiB | Viewed 774 times ]
File comment: All cleaned up and ready for new seal
crank seal CA pILOT 002.jpg
crank seal CA pILOT 002.jpg [ 45.36 KiB | Viewed 774 times ]
File comment: All sealed up and no leaks!!
crank seal CA pILOT 003.jpg
crank seal CA pILOT 003.jpg [ 67.93 KiB | Viewed 774 times ]
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 Post subject: Re: CA Pilot CSI-
PostPosted: Mon Mar 19, 2012 9:49 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5523
Location: New Jersey
Air leak test performed after resealing the exhaust flange, held 8 psi for over 1 hr. I rechecked the underside of the cases just to make sure everything was golden and it was. Installation of this Engine in the coming week should be performed hopefully(work is very very busy). Will post pictures.


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