ESE's works engine tuner

[husaberg]

That port map of yours doesn't look like the KR1S I worked on. There was no blind gully port and the auxiliary exhaust ports were 2 mm higher than the central exhaust.
And I didn't window the pistons; I replaced them with Yamaha TD2B racing pistons: lighter, one ring instead of two, and 1 mm less compression height which gave me the desired transfer timing without having to do anything to the ports.
Other mods: head inserts to compensate for the lower TDC, raising the central exhaust by 2 mm (which was the maximum that was allowed under the regulations), shortening the inlet rubbers as much as possible (6 mm I think it was) while keeping the standard 28 mm carbs (regulations again) and fitting own pipes. It produced 73 rear wheel-HP; quite enough for the then standard 400-class. 400 cc four-cylinder four-strokes against 250 cc two-stroke twins; let's show them how unfair that is .

that might be correct Frits, as that is a KR1 cylinder map, allthough probably from a tuned cylinder. the give-away is the port underneath the C-port. probably the one that makes Husaberg wonder if you windowed the psiton.

here is an original KR1S map, and as you notice : from the S onwards, they ditched that port (S cylinders are supposed to be the cylinders from the racing kit of the KR1)

http://i57.tinypic.com/k2fzmg.jpg

anyone have any idea about the purpose of the port under the C-port ?
as a sidenote : on mine the brigde between both (C and below) got missing (damn you Woessner ), so I removed it in the other cylinder also, never noticed any difference in performance.



edit : you don't happen to know CR ratio/squish ratio and height/... of that engine Frits ? How many rev's to get those 73HP ?
I use YZ125 '89 piston's in mine for the same reason, as they also have 1mm less compression height

Yes its the KR1 rather than the KR1S
On std 28mm carbs thats pretty impressive.
Some of the ones we got had 35mm PWK's

i will see if i can find another pic


i found this that says it goes nowhere and might need a hole in the piston to work.

[Hemi Makutu]

Laminar flow nozzles in the transfers and exhaust? Like used in water fountains. I was thinking about it a while back. Maybe not so good for a/f mixing, and hard to make enough room(and keep enough volume), especially in the transfers.

Could be, unless you have enough space to mill away the existing transfers, ( while retaining cylinder integrity)
& bond in a designer-shaped, flow-optimised, & multiplex-tubed, pre-fab unit.

[jonny quest]

Wobbly, regarding hydroformed pipes. It may work both ways.
Thundercat 900cc triple, individual pipes. Straight pipes on the dyno worked amazing over stock. Hand-built to chasis... they made same as stock. Refit pipes to have the longest straightest headers we could fit... piwer came back slightly. Made stampings off these, power came back some more.
Company building hydroformed pipes wanted our business, they built a set based on our dimensions... made more power than the stanpings.

[ief]

What differences in power are you talking about then johny?

[Larry Wiechman]

Wobbly, some time ago you offered a DXF that showed how to construct one of your KT100 pipes. I'd like to roll one of these up and give it a try!
Did the header used with this pipe conform to the 75% exhaust area rule?
Would it be beneficial to cool the header near the exhaust port flange?
Is the pipe straight or a 90° diffuser?

Thanks,
Larry Wiechman
wiechman@charter.net

[Larry Wiechman]

Wobbly, regarding hydroformed pipes. It may work both ways.
Thundercat 900cc triple, individual pipes. Straight pipes on the dyno worked amazing over stock. Hand-built to chasis... they made same as stock. Refit pipes to have the longest straightest headers we could fit... piwer came back slightly. Made stampings off these, power came back some more.
Company building hydroformed pipes wanted our business, they built a set based on our dimensions... made more power than the stanpings.

Was the same material thickness used for all the pipes?

[jonny quest]

20ga for handbuilt. 19ga for hydro and stampings

[adegnes]

Episode 3 of my garage vlog is out.

https://youtu.be/15El7vUgack

[wobbly]

The pumped up pipes used the same material, so that wasnt an issue.
We finally made a press tool and made the U bend front pipe header in two 1/2 pieces, as this was the vast time consumer .
This setup made around 1/2 Hp more than the cones did.
I believe the problem with pumped pipes is that there is no way to get a definite angle change between sections.
This is especially important where the rear cone starts, as there is always a big blend area where the wave action must
be " smeared " slightly.
In effect making the rear cone shorter.
Clamping/restraining the mid section did help alot though.
Pressed pipes can be much more accurate,and have definitive angle changes.
Honda have used this method forever in racebikes, and the KTM ones built by Harolds team were stunning,with formed
header/first diffuser - the rest in cones.
My opinion would be that if pumped pipes made more power, then the actual shape was different enough that the real dimensions of the as built part,
were " better " than the drawing used

Re the KT100 pipe.This is dead straight, the bend was in the tapered header that had a machined nozzle as part of the plate flange clamp.
The reducer nozzle varied from 32mm to 36mm ( the duct being 38 ) and each engine tuner had his nozzle of choice depending upon the tune.
I will have to search for the old hard drive that has the dxf on it, I have it somewhere, but I vowed never to make another after over 2000 hand built ones,the first
500 or so i even cut the patterns and drilled the rear cone holes by hand.
CAD and Lasers were a god send financially and brain damage wise back in the day.

[wobbly]

OK, found the old drive - here is the dxf and a couple of pics.
Bugger - dxf not allowed, can admin change this please.

[Larry Wiechman]

Bugger - dxf not allowed, can admin change this please.

Looks good!

Can you attach the DXF to an email and send it to wiechman@charter.net?

[Muciek]

More pics of the Ktm frr parts there are 4 cyl heads carbs and reeds http://www.pit-lane.biz/t118p25-gp12...tiques-ktm-frr

[TZ350]

http://www.rzrd500.com/500phpBB3/vie...11729&start=30

Interesting Engine build(S), lots of home brew and cunning ideas here.

[husaberg]

OK, found the old drive - here is the dxf and a couple of pics.
Bugger - dxf not allowed, can admin change this please.

Possibly.....
I thought i was on the list,
er no its not on the list.
Can you screenshot it as a word or Jpeg?
Word doc 2.00 MB

gif 768.0 KB

jpeg 768.0 KB

jpg 768.0 KB

kmz 2.00 MB

mp3 1.00 MB

pdf 2.00 MB


what is the size?
Request sent to MR T.

[TZ350]

.
The real deal, a performance 2T Two Stroke successfully running an electronic fuel injection system.

E85 at work

Kawasaki F86M BigHorn 350cc Air Cooled, E85 and Fuel Injected .......

Here is the EFI at work.

F86M dyno graph.