RPE Engine Refresh #15

Fitted the new Extreme cams, positioned the exhaust and inlet cams by the marks on the sprockets, made sure that the notches on the end of the cams were in position with the inlet facing upwards at 12 o'clock and the exhaust at about 11 o'clock. Also checked that the lobes were in position.

Fitted the cam chain tensioner, checked that the head pin was in good condition and also that the rubber head was ok. Fitted a new gasket and bolted in to place, fitted the chain guide, then removed the tie wraps and manually turned the engine by the crank.

Will need to check the timing with a dial gauge to properly set up the cam timing. Have ordered a timing wheel, dial gauge and a piston stop, will finalise the timing when these arrive.

RPE Engine Refresh #14

Cleaned the cylinders and lubricated with engine oil around the bores. Fitted a new Cometic head gasket and new locating pins. Fitted the head and pushed down in to place.

Cleaned the head bolts and oiled the shafts, threads, heads and also the washers. Fitted the bolts and then tightened by hand. From the centre outwards in order I tightened the bolts and torqued to 25NM and then to 52NM. The torque for the head bolts is lower than the turbo engine as this engine is fitted with stock bolts.

Re fitted the oil line from the head to the crankcase.

RPE Engine Refresh #13

The threads on a couple of the exhaust ports were looking a bit tired, so decided to Helicoil the threads with stainless steel 3d coils. 

RPE Engine Refresh #12

Trial fitted the new Extreme Engines cams and adjusted the cam lash. Set the valve lash on the inlet cam to 0.008" and the exhaust cam to 0.010". Used various shims and recorded the size of shim and gap for each valve. 

Found on the inlet that 8 thou was inbetween two shim sizes and could get 0.007" or 0.009" but not 0.008". In the end I decided to go with 0.009" as there will be expansion when the engine is running.

Torque Conversion Chart

When I use my small torque wrench it has a range in Inch Pounds and as most torque settings in the Hayabusa manual is in Newton Meters I have put together this conversion chart.

Turbo Engine #7

Cleaned the bores and pistons with brake cleaner and a soft cloth to remove the debris. Checked the piston part numbers and confirmed that they are 81mm Wiseco low compression turbo pistons. I re oiled the barrels and fitted the head.

Next I re oiled the cylinder head studs making sure to oil the washers and shafts. I then tightened from the centre out in a diagonal pattern. Next I torqued the bolts to 50NM in the same order and then to 100NM.

Turbo Engine #6

The head looks like its in great condition and has freshly has had the valves ground. I checked the shim sizes and gaps which all look ok. I removed the PAIR hose mounting studs and then tapped the holes. I fitted M6 grub screws to blank off the holes.

I removed the water outlet from the bottom of the head and replaced it with an aluminium blanking plug from Extreme Engines.

Turbo Engine #5

Removed the camshaft journal holder bolts, the cam chain guide and the oil pipe joining the covers. Next removed the cam journal covers and the cams.

The head was clamped down tightly with 12mm high tensile studs with hex drive heads. I undid these with a  breaker bar and cracked each bolt quarter of a turn from the centre out on a diagonal basis. Then removed the bolts and washers, I then removed the head to reveal the pistons.

When looking at the pistons, they certainly look brand new and have never run. Guess that Damian was right about the dirt in the bores, there was even a couple of dead insects in there with the cigarette ash!!