What did you do today? Cobba's rebuild

[Trixed]

The ceramic coating on the headers is top notch. I need to get mine done too now. Good idea to prevent polishing and yellowing of stainless steel then

[cobbadiggabuddyblooo]

Motor is finally completed minus the top sump gasket.
Suppose I'll look at painting the motor once the rain has gone.
I just need to see how much access I have to retention the head bolts with the motor bolted into the frame and see what I'm in for fitting it back into the frame.
New rear wheel dampers should arrived by the end of the month so not too much stopping me now.
Start of Autumn and with the weather cooling a little, rainy season should be finished too by the time its all mobile.

Finished product.

Light weight 12:1 ceramic coated Arias 878 pistons
Carrillo Rods
Lightened and balanced crank
1mm oversized valves
kent cams dialed with slotted sprockets
Flowed head with ceramic coated chambers, valves and ports
leightweight Ceramic coated 2-1 Akrapovic exhaust set up for 02 sensors
41mm FCR's
catch tank and 1 way valve engine breather system
Sigma slipper clutch
D.I.D. 520 ZVM-X gold chain
Ignitech TCIP4 prog ignition
Dynatec DC-3 coils
light weight Litium battery
Koso RX2-N digital dash
reworked full racetec internal '99 R1 forks
Billet trees with stepped top yoke with 30mm offset
40mm raised clip ons
Ohlins rear
Coerce rearsets
Dymag SB5 lightweight magnesium wheels
lightweight 220mm rear disc
Moriwaki fully floating 5mm/298mm front discs
R1 gold spot callipers with DP pads

larger '99 R6 radiator
and a xjr400 oil cooler to be fitted if needed

striving for 100/100 HP/Nm rear wheel
Final weight wet on the road with full tank, 18L fuel 189 Kg...... 20kg lighter than std trim (209kg)
around 3kg lighter in track trim

[cobbadiggabuddyblooo]

First impression on the motor...
Shame they where not std in this format, they would have sold 100 fold more.
Motor kicked over within seconds of hitting the starter button.
Ran it up to running temp and let it cool overnite .
It was hot to work through the day so i just drained the oil and changed the plugs , oil and air filters.
Later in the afternoon I removed the radiator and cams again to access the head bolts and re tensioned the head and checked clearance again. All over 0.15mm so no issues, better loose than tight.
I'll redo the valve clearances again at the next service in a couple of hundred Km's .
I bedded the rings at 11' o'clock at night when nice and cool for 1/2 hr loading it up and going through the gears and it wasn't taking long before 6000rpm was alight on the dash .
Today's run was 100kms along the highway running down to 90kph and then throttle on in top gear loading the motor in little sprints.

So a bit of a summary.
Motor spins up a lot faster now even with the taller gearing 17-41.
Running 16-41 on the std spare motor that was removed.
Over 1/2 kg weight removed from the rotating mass within the motor, clutch and front sprocket compared to a std motor.
Add this to the dymags, even simple things like 520 chain and light weight rear sprocket , they all start to add up.
It doesn't take long before I'm reaching for another gear..
The Koso dash holds the final led on the taco for 2 seconds after each gear change so I'm finding its not long after the 6000rpm led goes out I'm there again.
I'm glad I upgraded the brakes as they certainly get used now..

Temperature wise, I'm finding the same running temps as with the std motor between 76-82*c
But if stopped at traffic lights for 2 minutes or more the thermo fan kicks in at 95*c and keeps the temp under 98*c ..
I might add this was at midday and 30*c.
Oil temp hasn't risen above 80*c yet so all good there too.

Another ride planned for Friday to let it breathe a little more so a spirited run up over the mountains is in order I feel.
Sigma slipper clutch feels light (3 std and 3 H/D springs) with a slight clicking feeling just as you pull on the clutch lever, so a soon as you feel that just slip it up another gear so very little lever is used on each change and change down is flawless without the clutch.

The motor seems to purr now and has a nice growl when opened up.
Pulls like a train
Handles like a dream
Stops on a dime so I'm happy

[Trixed]

I felt the throttle and can attest the response almost instantaneous, feels extremely light and revs like an angry beast.

[sanddune51]

Sounds from all you've said that you've built the perfect Trx
Well done mate!

Mark.

[QuickDraw]

Looking forward to hearing it Brian! I'm still a little way off with mine... flat out with work. Decals ordered. Panels file-finished and ready for final undercoat & block-back.

[Trixed]

Basically everything from the carbies, induction, valves, cams, pistons, crank, headers, exhaust, breathers, clutch, sprockets, chain, and wheels has been lightened or optimised. I think this is the furthest any Trx had gone bar a turbo setup on top.
Having riden the bike with old motor was impressive enough. All this takes it to another level altogether. My prediction is 105-110 bhp.

[cobbadiggabuddyblooo]

I'd dearly love those figures from the TRX but
The motor hasn't been built though for outright horsepower but torque and acceleration otherwise
2mm oversize valves , an Over or Nojima system with V2 cams, shorter bellmouths would be used.

The gains or extra acceleration you could feel Udaysen was from the lighter weight wheels,
decent bearings, 520 chain and just overall weight reduction.
all those 1/2 and 1%ers start to add up if they all compliment each other and not robbing Peter to pay Paul.

I was looking for a figure close to 100hp and 100Nm so I feel I must be close ..
I'll be happy with that..

[rjen]

Awesome work! Sounds like all the effort has paid off!

[dandywarhol]

[cobbadiggabuddyblooo]

Yes all came together well and up over Mt Glorious with Rod the other day I had an Englishman on a 2011 Aprillia eating my dust the whole way. Never ran over 7,000rpm and excellent acceleration out of the corners.
He was really impressed on how well planted it was through the corners and spoke about how the TRX where giving the Ducati's a good run for their money in the racing over in the U.K.
His mate was riding a trx in the series at some time and was fairly impressed with how the old dogs went.
I had the head off again yesterday as I left it just a little long between re tensioning the head back down.( first time is used the hylomar spray too and feel it may have been a little thin.)
I took my time in re tensioning this time at stages with an hr between each increase in torque till I finally reached 40Nm.
I'll do 1 heat cycle and retension, another at 200km and again at 400km and by the time 600km comes around I'll be due to do the clearances and oil change (1,000km total) so ill check it again and all should be good.

[cobbadiggabuddyblooo]

The story only gets better.
After fitting the FCR's over 6 yrs ago I figured I might as well give them a clean and set everything back to the default fcr settings.
Still with all std jets but I place the needle back to the middle or 4th position ( which is std) and gave it a bit more fuel.
Why read the plugs when I can read the pistons and chambers
Quick 15minute ride locally and Idling a little smoother and twist the throttle in second out of a corner and you feel the back end starting to break away and the front wheel wanting to look for the stars.

Twist the throttle from 3,500rpm and let it breathe and it just asks for more.
It felt a little hesitant and lean over Mt Glorious so I'll go for a squirt tomorrow to see how things go.

[cobbadiggabuddyblooo]

Installed a revised ignition map today and bike sounds better, I have my smooth unloaded gear changes back and bike just wants to rev faster and keep pulling after 7,000rpm when you twist the throttle . It's taken away the slight vibration I was getting through the pegs and bars so it's all slowly falling into place.
My O2 sensor kit arrived 5 minutes ago so looks like I'll be doing a little rewiring with the new loom through the week.
perfect as they are predicting rain anyhow.
So I can see if my assumption of lifting the needles was only feeding the default TCIP4 curve which is now working as an advanced timing map due to the higher compression.
More fuel making for a slower burn, richer mix to compensate for the advanced timing to get timing back to optimum. Not the way to go about things.

So I'm very happy with the timing improvements with this new program.
Now it's time to check my air/fuel ratio..

[Con Rod]

Hey Cobba

I have an ignition program you might like to try as a start instead of the stock program,

PM me your e-mail and I will send it through

[Killerwhale]

Hey Cobba

I have an ignition program you might like to try as a start instead of the stock program,

PM me your e-mail and I will send it through

Mail me all maps I love to try stuff out!!
snuffy_snuffer@hotmail.com