Look at this pic, with the old seal installed and the cut away bearing race you can see the opening is almost blocked off completly

Now with the bearing race installed and using a mirror to see the opening the arrows point to the areas it will be slotted for more flow

Some material removed increasing the distribution area.

A little more hoserized crank case mods

I will sped a few more hours "hoserizing" or enhancing the crank cases.

Here is the cylinder bolted to 1/2 the crank case to give you an idea what it looks like inside, not much I can do here until I have the new cylinder, plenty of miss match, casting flaws etc.

Get the creative juices flowing.

More

Ok lets add the crankshaft, case matching

removing casting flaws
hoserized cases

Ok remove the crankshaft and insert the piston

Hoser,

Looking good,

90 HP!! I never thought it possible, How much you think your making with the 440?

TD

The 440 is detuned from the way it came from the factory, I am running a 2 into 1 pipe and a single 38mm carb and manifold off a watercraft, the intake tract has been lengthen more over the sleds dual 38mm setup, my guess would be a honest 70 hp, I don't see the need for much more hp, with this hp I quickly exceed the brakes and suspensions limitations, its nice in the wide open areas where you have all kinds of room but its a hand full on tight trails, tire spin is still a issue, braking on hard pack is a issue because of all the extra momentum you can build up with the extra power sooner than using a lesser powered Engine.

I talked to TD and the old cylinder and head is in fact for sale make an offer.

Its on its second bore it needs bored again unless you want to run the huge clearances some like to run with the wisecos.

I also have he 500 big bore if you want 2 to play with http://pilotodyssey.com/500cc.htm I never ran it I picked it up off ebay and never got a chance to try it.

"H" I have not seen it on others. I do like the way you tappered the hole to achieve a funnel effect. I have not considered the bearing mod but have increase hole and tapper. The bearing side mod I do feel will enhanse the effect of tappering and provide better flow and vacum effect as the crank rotates at high speed. Bigger hole need more flow. I also think this will increse the seal life as well. Maybe no more spun bearing for that motor (( Internal Combustion Engine ? )), a little lock tight should work. Nice work and I kept on watching and learning. Even If had seen else were please post I some times forget what I see and need a reminder from time to time. Thanks

Best packing job I seen to date.

Pilot Engine fits perfectly

Each piece is notched and custom fit to lock the Engine in place.

Even the top piece is well thought out it has notches to ease removal, not sure what kind of foam this is, its great stuff, maybe TD can fill us in.

Hoser,

The Foam is 2" Thick 1.7 Lb Density Polyethelyne. It's made by either Sealed Air or Pactiv.There may be other manufactures in other parts of the country. Any Packaging or Crating company usually stocks it.

That Engine sure looks good.

TD

Hoser,

Finally got it picked up tonight looks great, the box held up really well.

Hopefully I can start install tomorrow.

Thanks Again,
TD

Hoser,

Just an update,

It's up and running got about 1 1/2 hours on it, Needs some carb work, now it's just a tuning issue,
everything else looks and sounds fantastic.

Thanks Again,
TD


P.S. Any word from the Machine Shop on the new heads

Can you post details on your jetting and its changes ?

I will call about the heads today no reply to my email.

Hoser, I ordered a Digatron yesterday so I could document the jetting changes, I won't start the tuning until I get it in.

Where should the EGT Probe be placed on a rev pipe?

TD

Seen this? viewtopic.php?t=1932

I locate mine about 3" from the end of the pipe or about 6" from the face of the piston, you need to be out of the 'wet line', you need to take into consideration the springs location when you locate the probe, I have seen others locate them on the bottom side of the pipe too, my rev pipe came with the hole already drilled so that's what I went with and where I located the hole on my torque pipe too.

Please remove the pipe ( I know its a pain in the ass) to drill the hole, look at the animated gif in the link I gave above see the returning pulse wave I hate to see a metal shaving sucked back into the Engine.

Pipe will not be drilled on the Engine, I was wondering if the line would be developed well enough to tell,I'll look at the torque pipe (it may be different from the old cylinder)
Here's what I've learned so far, The porting on the old Cylinder was off so far it was causing fuel pump problems.
It's night and day difference on starting, before I had to block off the air tubes to get it to pull fuel to start,Now it's bump the gas and the starter and it's running.
TD