ESE's works engine tuner

[speedpro]

Also, what method are you using to locate the head to stock cylinders? With your skills it would be an idea to get the cylinders and match head to cylinder with whatever method you use.

[husaberg]

These seem to be the two biggest stumbling blocks on your wish list, Husa. But maybe we can remove both of them.
Water cooled cases are fine, but another option is insulating the inside of the cases, where the mixture comes in contact with the case walls.
My mate Martijn Stehouwer of Emot.nl offers an amazingly effective heat insulation lacquer. He became twice European champion using the stuff.
Attachment 309968

Next: your ignition. You can put the ignition pick-up on the primary drive side, but you canalso go for the Aprilia RSA solution and put it in the outer crankcase wall where it is triggered by a notch in the crankshaft circumference.
Attachment 309971Attachment 309972Attachment 309973Attachment 309974

Or you can put the ignition at the rotary disk side anyway: converting a non-rotary engine to the 24/7 inlet system is simpler than converting it to rotary....

Thank's Frits you are to kind, my biggest stumbling block is my lazyiness and my chronic procrastination and general lack of talent.
I have raided Emot site already. The paint was Russian if memory serves me right and used for stuff as diverse as missiles or rockets and houses.
I are wanting to have a go at making cases. just to do something different. That way I can fit everything on the whish list in.
I are pretty sure Honda will have used the same tooth pattern elsewhere, I will find it. After all I only have 10 more years to get it finished now.
To fit it on a std primary drive side I need a long snouted crank I think I found one last night in the edit above.
oh well here it is for those unwilling to go back a page

Its not perfect its bloody obscure but I think it will work.

The idea in my mind for mounting the stator on the clutch side was because the clutch was already poking out that side anyway so it wouldn't make it any wider.
Wob hopefully still has the Cr ignition and the ignitec tucked away in his emporium which although it is ino where as neat as the Aprilia's Selecta, it should do the job.
The 24/7 is something that does interest me very much but I think Flettner was doing something along those lines last week, he's likely finished it already.

Any idea what a water cooled case is actually worth in HP terms.
Also if I way ask why was the balance shaft mounted so low on the RSW was it mealy a Rotax carry over?
The ignition pick up on the crank wheels was for accuracy is that right? as the shafts flapped about to much?

[Sketchy_Racer]

Handy, you've already smashed the ceramic off the plug. Drawn with B8ES size rather than B8HS? A better option I think. Though if going to the trouble I'd probably check if a smaller diameter plug has advantages. I "know someone" who would be interested in a couple. 52mm bore and profiled for a KSI KT100 piston, 50% squish, 0.65 squish clearance, and 14.5:1 compression so about 7.3cc trapped volume.

Plug is just in there for a indicative thread length. That chamber profile is what's in my motor at the moment. Makes the same power as the RM85 (before it gets hot)

I have a model for Yamaha KT piston dome but not the KSI ones, are the domes different?

I'll be putting alignment dowels into accurately align the head to the barrel.

[Peter1962]

On page 962 and 963 Frits talked about a Zabel engine he was working on. Incredible engine used in sidecar MX .
I found this article about a guy who mounted a zabel in a motocross bike. Quite interesting and very impressive to say the least. The exhaust is a work of art.
http://www.sidecarcross.de/hofmann/news/Devil%20007.pdf

[Frits Overmars]

Any idea what a water cooled case is actually worth in HP terms.

I haven't got the old Rotax129-data at hand but I guesstimate: about 5 % (HP figures must always be seen in relation to the total engine power; percentages are universally usable).

why was the balance shaft mounted so low on the RSW was it mealy a Rotax carry over?

Yep. And you're too kind calling it a balance shaft. It was grossly offset to the left so it turned the engine vibration into a rocking couple.
Moreover, it is a cross between a cream whipper and a gear pump; running so low, immersed in gearbox oil and in such tight casings, it absorbs a lot of power.
Not the sort of solution I would normally expect from a clever company like Rotax. Must have been a quick-and-dirty 'improvement' on the shaft-less Rotax124-engine.

The ignition pick up on the crank wheels was for accuracy is that right? as the shafts flapped about to much?

Yep again.

[wobbly]

Re the head insert Sketchy.
Get rid of the stress raiser corners with rads, will make the insert much stronger and able to transfer some of the combustion load up to
the cover for support.
As you appear to have the water inlet and outlet in the head, put a blanking wall across the head cover that fits closely to the chamber, only allowing water to flow
across the head thru the small gap close to the plug.
This will force most of the water down into the cylinder, so you will need to blank off the holes on each side of the head, so the flow within the cylinder has
to go across the transfer outer walls, then travel up from around the EX port into the head,and exit.

Sorry dribbling again, didnt read properly that the cylinder was aircooled - dumbarse.

[RAW]

Yep. And you're too kind calling it a balance shaft. It was grossly offset to the left so it turned the engine vibration into a rocking couple.
Moreover, it is a cross between a cream whipper and a gear pump; running so low, immersed in gearbox oil and in such tight casings, it absorbs a lot of power.
Not the sort of solution I would normally expect from a clever company like Rotax. Must have been a quick-and-dirty 'improvement' on the shaft-less Rotax124-engine.


Frits I'm about to machine up a couple of them there ice cream whips for Lozza, best we rethink this and improve things rather than just copy a poor mistake. Any chance yourself or perhaps Wobbly would take myself & the readers through the process of how to work out the balance shaft. using the RSW shaft as pictured & how to design a new full circle unit with tungsten weights to retrofit in replacement of the original unit ?

[Frits Overmars]

Frits I'm about to machine up a couple of them there ice cream whips for Lozza, best we rethink this and improve things rather than just copy a poor mistake. Any chance yourself or perhaps Wobbly would work out the weights & positions if we were to build a full circle one to retrofit in replace of the original unit ?

That would take more time than I have available right now. What you can do is fit a sleeve around it. It won't do much good for the viscous drag but at least you won't have a cream whipper any more.
Inserting mallory slugs may allow you to reduce the outer diameter; that would reduce the drag. But it won't reduce the rocking couple. For that you would need a shaft running across the engine, with bob-weights left and right, like on the RSA125

[RAW]

Thanks Frits. You've made it easy again.

[lodgernz]

... But it won't reduce the rocking couple. For that you would need a shaft running across the engine, with bob-weights left and right, like on the RSA125

...or a single weight running right across the engine, like the Honda Mission engines (NSR50, 75, 80 etc)

[husaberg]

The CRF150R and the NSR125/150 has a two sided balance shaft with one side built into gears.

Other Hondas use a one lobe design in the middle Yamaha and Suzuki also do the same.

The first one I seen with a gear build into the balance shaft was the NS500/RS500

The MB50 NSR75 MB100 etc is clever in that it is driven from the clutch.

Various others

The latest KTM used a combined water pump balance gear set up
http://www.kiwibiker.co.nz/forums/al...hmentid=307181

[wobbly]

Rethinking the aircooled cylinder with water cooled head - is it possible to cut a couple of side trenches in the cylinder top deck, between the studs and force some water
into the hottest area at the top of the bore.

[F5 Dave]

I've just disabled balancer on a Derbi 50 as an experiment. Didn't notice an increased vib at racing speeds. Might leave it off. Unless can be convinced otherwise. Engine obviously spins somewhat faster than road bike it was designed for.

[ken seeber]

Frits I'm about to machine up a couple of them there ice cream whips for Lozza, best we rethink this and improve things rather than just copy a poor mistake. Any chance yourself or perhaps Wobbly would take myself & the readers through the process of how to work out the balance shaft. using the RSW shaft as pictured & how to design a new full circle unit with tungsten weights to retrofit in replacement of the original unit ?

Rick,
Maybe this article can be of some help
Ken

[husaberg]

Seen this when I was looking for crankseals
Dimensions of the Koing Flying web crank.
http://konny.cz/price_b/2s.htm