ESE's works engine tuner

[skako]

Skako, the problem you have is that the first book uses the homentropic method of characteristics (MoC) to calculate gasdynamics. The problem is that the MoC is a first order method and it is not conservative so it does not preserve mass or energy. It can gain or loose mass and energy. To preserve mass and energy requires a conservative method, usually a two-step finite difference method like Lax-Wendroff or Harten-Lax-Van Leer with some sort of correction, or the GPB method that Prof Blair developed and use in his second book.

Even so the MoC has been used for many years with great success but more to study trends and not more absolute values.

I do not know your background so do not know if my answer above helps you. Hopefully I have not offended you.

Vannik,
Your answer means a lot to me.
These are new guidelines for me that need to be studied.
I do all this as a hobby and a desire for more knowledge.
Do I need more knowledge at this age?
Probably not. I believe that the majority could agree with that!
But there is something inside me, (perhaps a remnant from my old student days), which makes me want to learn more.
It must be one of the reasons that I worked outside of my engineering profession for many years.
I kind of miss that today. What I do at home as a hobby, it makes me happier, without obligations and stress about whether I will succeed.
It's all good exercise for my brain. I hope you understood me.
Your answer means a lot to me and will be useful to me.
Thank you very much!

[TZ350]

From what i understand with the telflon seals i think only the inner ring that contacts the shaft lip part of the seal is made of or maybe even coated with Teflon the rest will be some other form f "rubber" That might explain the variable results?

I think you are right. The Yamaha ones only had a Teflon coating on the lip part. It may well have been the lip that was expanding and not the Teflon itself. I never thought of that.

[TZ350]

.


More problems with the Kawasaki. It is leaking around the base of the cylinder. To much oil to ignore.

To get the 250 barrel of choice to fit I had to fit a spacer plate. I glued and screwed it down to the case.

Then milled it off square and flat.

The joint now leaks, I am not sure if its the spacer to case joint or spacer to cylinder joint leaking.

Or worse, the studs are pulling loose in the case.

[pete376403]

.


More problems with the Kawasaki. It is leaking around the base of the cylinder. To much oil to ignore.

To get the 250 barrel of choice to fit I had to fit a spacer plate. I glued and screwed it down to the case.

Then milled it off square and flat.

The joint now leaks, I am not sure if its the spacer to case joint or spacer to cylinder joint leaking.

Or worse, the studs are pulling loose in the case.

Harry Klemms website describing preparing the Bighorn racers notes that Kawasaki did not mill the cases as a pair at the barrel joint. You milled the spacer plate, but did you mill the cases first?

[husaberg]

.


More problems with the Kawasaki. It is leaking around the base of the cylinder. To much oil to ignore.

To get the 250 barrel of choice to fit I had to fit a spacer plate. I glued and screwed it down to the case.

Then milled it off square and flat.

The joint now leaks, I am not sure if its the spacer to case joint or spacer to cylinder joint leaking.

Or worse, the studs are pulling loose in the case.

With my limited Experience of a few Honda 2 and 4t with Spacer plates never had issues with using a gasket either side ,but that was with through studs, That was also only with annealed aluminum and less than 1.6mm thick or so spacers.
What did you do for the GPNSR spacers?

[skako]

Hi,
Here are some more photos of the 7-speed gearbox that I made.
At that time, it was unique in our region.
To this day, someone else probably made it as a rarity.
This gearbox is suitable for all Tomos mopeds that had a gearbox with 4 or 5 speeds in the original version.
To make the 7-speed gearbox for Tomos, I was inspired by the Cagiva Freccia 125 C12R.
I could only dream about her at that time and read about her in the newspaper.
At that time, in our region, we only had domestic Tomos mopeds.

[Vannik]

is this the second book?

Attachment 352201

Yes, that is the second book.

[TZ350]

Harry Klemms website describing preparing the Bighorn racers notes that Kawasaki did not mill the cases as a pair at the barrel joint. You milled the spacer plate, but did you mill the cases first?

No. But the spacer plate halves were permanently fastened with screws and glued with JB Weld to the cases then they were milled flat.

What did you do for the GPNSR spacers?

The GP/NSR 110cc engine spacer plates are 12mm thick. Gaskets both sides usually, depending on stack height to get 0,6mm squish. 3mm trimmed from the top of the cylinder to get the port timing correct.

[Grumph]

.


More problems with the Kawasaki. It is leaking around the base of the cylinder. To much oil to ignore.

To get the 250 barrel of choice to fit I had to fit a spacer plate. I glued and screwed it down to the case.

Then milled it off square and flat.

The joint now leaks, I am not sure if its the spacer to case joint or spacer to cylinder joint leaking.

Or worse, the studs are pulling loose in the case.

Was this while the main seal was also leaking oil into the inlet tract ? If it was, and it hadn't leaked before, try it again once you have the new seal in place.
Do you do leakdown testing of the engine ?

[pete376403]

No. But the spacer plate halves were permanently fastened with screws and glued with JB Weld to the cases then they were milled flat.

From Klemms website:"Base Gasket Surface - In the 1970s, it was very common for manufactures to make crankcase halves as individual parts, not as matched pairs. Given this, there were often significant variations in base gasket surface height between the left and right case halves. This difference in heights results in the cylinder not sitting square on the cases, not to mention significant airleak risks at the case center joint. To resolve these problems, we assemble the two empty case halves together, and mount them in a mill to cut the base gasket surface perfectly flat, and square to the crankshaft. Of the four running machines we bought for our project, all four has significantly mis-matched base gasket surfaces. This service included as part of our Engine Blueprint Assembly, or can be done as a separate machining operation."

So even if your new top surface was flat, is there any chance that tightening the head bolts could have distorted the plate to allow leakage? On the bright side, oil coming out is better than air going in (and causing a lean seizure)

[F5 Dave]

Exactly my thought. Block inlet and outlet one with a Schrader valve and small pressure gauge fitted in the plate is usually easier. Although I have a T piece both fit in and go in through the sparkplug.

7psi and spray some soapy water at the joint. Will be pretty obvious fast.

[Wos]

.


More problems with the Kawasaki. It is leaking around the base of the cylinder. To much oil to ignore.

To get the 250 barrel of choice to fit I had to fit a spacer plate. I glued and screwed it down to the case.

Then milled it off square and flat.

The joint now leaks, I am not sure if its the spacer to case joint or spacer to cylinder joint leaking.

Or worse, the studs are pulling loose in the case.

Think you should avoid smallest skratch going direktly from insinde to outside.

Hard to recognise on a foto

Take the stud bolts out and grind the upper surface with a fin bankstone

Do not use paper gasket thicker then 0,4 mm...thicker sits down to much in a whihle and minimises the squish gap

Most time we use only special Silikone for spacers...

Goooood luck! 😉

Wolfgang

[Frits Overmars]

Do I need more knowledge at this age?

I cannot speak for you Skako, but me, I am constantly held back by the limits of my knowledge. Whatever its depth, it will never be enough.
What has age got to do with it? I believe that the moment you decide that enough is enough, that's the moment you are old, regardless of your physical age.
Me, I'd like to keep struggling on for a while

[skako]

I cannot speak for you Skako, but me, I am constantly held back by the limits of my knowledge. Whatever its depth, it will never be enough.
What has age got to do with it? I believe that the moment you decide that enough is enough, that's the moment you are old, independent of your physical age.
Me, I'd like to keep struggling on for a while

I agree, you say it well.

[TZ350]

Think you should avoid smallest scratch going directly from inside to outside. Hard to recognize on a photo. Wolfgang

When I lift the barrel I will check. Thanks for the tip.

So even if your new top surface was flat, is there any chance that tightening the head bolts could have distorted the plate to allow leakage?

Another thing I did not think of. I suppose it is possible. Next time its running hard on the dyno I will see if I can tell which side of the spacer plate is leaking.