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CA Pilot CSI- updated it's back!!
http://www.pilotodyssey.com/PO/viewtopic.php?f=34&t=9079
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Author:  fully [ Sun Feb 19, 2012 10:50 pm ]
Post subject:  Re: CA Pilot CSI-

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

Author:  mudbogger [ Mon Feb 20, 2012 8:03 pm ]
Post subject:  Re: CA Pilot CSI-

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.

Author:  hoser [ Sat Feb 25, 2012 5:42 pm ]
Post subject:  Re: CA Pilot CSI-

viewtopic.php?f=4&t=6158&p=52620

Check your PM murray

Author:  mudbogger [ Sat Feb 25, 2012 7:29 pm ]
Post subject:  Re: CA Pilot CSI-

download/file.php?id=21207

thanks Hoser

Author:  pilotscott [ Sat Feb 25, 2012 9:25 pm ]
Post subject:  Re: CA Pilot CSI-

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?

Author:  mudbogger [ Sat Feb 25, 2012 9:56 pm ]
Post subject:  Re: CA Pilot CSI-

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! :-)

Author:  mudbogger [ Fri Mar 02, 2012 9:31 pm ]
Post subject:  Re: CA Pilot CSI-

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!

Author:  mudbogger [ Sun Mar 04, 2012 10:28 am ]
Post subject:  Re: CA Pilot CSI-

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.

Author:  mudbogger [ Sat Mar 17, 2012 1:08 pm ]
Post subject:  Re: CA Pilot CSI-

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 18497 times ]
File comment: lightly sanded the surfaces
CA pilot engine specs 002.jpg
CA pilot engine specs 002.jpg [ 53.12 KiB | Viewed 18497 times ]
CA pilot engine specs 003.jpg
CA pilot engine specs 003.jpg [ 34.92 KiB | Viewed 18497 times ]
CA pilot engine specs 006.jpg
CA pilot engine specs 006.jpg [ 43.57 KiB | Viewed 18497 times ]
File comment: piston to wall clearance
CA pilot engine specs 007.jpg
CA pilot engine specs 007.jpg [ 41.8 KiB | Viewed 18497 times ]
File comment: again piston to wall clearances
CA pilot engine specs 008.jpg
CA pilot engine specs 008.jpg [ 42.59 KiB | Viewed 18497 times ]

Author:  hoser [ Sat Mar 17, 2012 1:13 pm ]
Post subject:  Re: CA Pilot CSI-

"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.

Author:  mudbogger [ Sat Mar 17, 2012 1:43 pm ]
Post subject:  Re: CA Pilot CSI-

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.

Author:  mudbogger [ Sat Mar 17, 2012 2:17 pm ]
Post subject:  Re: CA Pilot CSI-

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 18493 times ]
CA pilot new piston 003.jpg
CA pilot new piston 003.jpg [ 44.77 KiB | Viewed 18493 times ]
CA pilot new piston 001.jpg
CA pilot new piston 001.jpg [ 50.28 KiB | Viewed 18493 times ]

Author:  mudbogger [ Sat Mar 17, 2012 2:20 pm ]
Post subject:  Re: CA Pilot CSI-

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.

Author:  hoser [ Sat Mar 17, 2012 2:22 pm ]
Post subject:  Re: CA Pilot CSI-

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.

Author:  mudbogger [ Sat Mar 17, 2012 3:01 pm ]
Post subject:  Re: CA Pilot CSI-

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!!

Author:  mudbogger [ Sat Mar 17, 2012 4:19 pm ]
Post subject:  Re: CA Pilot CSI-

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 18477 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 18477 times ]
ca motor pictures 003.jpg
ca motor pictures 003.jpg [ 64.29 KiB | Viewed 18477 times ]

Author:  scpilot66 [ Sat Mar 17, 2012 5:55 pm ]
Post subject:  Re: CA Pilot CSI-

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.

Author:  mudbogger [ Sat Mar 17, 2012 8:13 pm ]
Post subject:  Re: CA Pilot CSI-

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

Author:  mudbogger [ Sat Mar 17, 2012 8:14 pm ]
Post subject:  Re: CA Pilot CSI-

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.

Author:  mudbogger [ Sun Mar 18, 2012 7:23 pm ]
Post subject:  Re: CA Pilot CSI-

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 18457 times ]
clutch seal 003.jpg
clutch seal 003.jpg [ 56.7 KiB | Viewed 18457 times ]

Author:  davidafco [ Sun Mar 18, 2012 7:35 pm ]
Post subject:  Re: CA Pilot CSI-

That can be replaced without taking the bottom end apart cant it?

Author:  rmesser [ Sun Mar 18, 2012 7:59 pm ]
Post subject:  Re: CA Pilot CSI-

Do you need to replace?

Author:  hoser [ Sun Mar 18, 2012 8:02 pm ]
Post subject:  Re: CA Pilot CSI-

viewtopic.php?f=25&t=5597

Author:  mudbogger [ Sun Mar 18, 2012 8:44 pm ]
Post subject:  Re: CA Pilot CSI-

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 18438 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 18438 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 18438 times ]

Author:  mudbogger [ Mon Mar 19, 2012 9:49 pm ]
Post subject:  Re: CA Pilot CSI-

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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