SuzukiSavage.com - 100 mm ?

LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10604 Oklahoma Gender:	100 mm ? 10/10/12 at 05:06:23 Just received a new JE 100mm piston for the DR650; will try building an engine from left over parts to see if it will be workable. How long will it survive ? .
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: 100 mm ? Reply #1 - 10/10/12 at 05:51:44 LANCER wrote on 10/10/12 at 05:06:23: Just received a new JE 100mm piston for the DR650; will try building an engine from left over parts to see if it will be workable. How long will it survive ? . 28
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17821 Camp Springs, Kentucky Gender:	Re: 100 mm ? Reply #2 - 10/10/12 at 06:09:08 I got some low mileage valve seals and a lightly used right crank bearing I can donate.
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Paraquat Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2206	Re: 100 mm ? Reply #3 - 10/10/12 at 06:13:43 How much of the steel sleeve is left over? Edit: Should say cast. --Steve
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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10604 Oklahoma Gender:	Re: 100 mm ? Reply #4 - 10/10/12 at 11:03:34 Paraquat wrote on 10/10/12 at 06:13:43: How much of the steel sleeve is left over? Edit: Should say cast. --Steve I believe there will be about 1-1.5mm of sleeve left after boring.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17821 Camp Springs, Kentucky Gender:	Re: 100 mm ? Reply #5 - 10/10/12 at 12:25:25 738 cc of ground pounding super thumping....Vrroom, Vroom.....Crunch! Dang!
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28376 Tucson Az Gender:	Re: 100 mm ? Reply #6 - 10/10/12 at 12:37:26 Gyrobob wrote on 10/10/12 at 05:51:44: LANCER wrote on 10/10/12 at 05:06:23: Just received a new JE 100mm piston for the DR650; will try building an engine from left over parts to see if it will be workable. How long will it survive ? . 28 seconds?... minutes?... miles?... My guess is 42... ...
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LANCER

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Oklahoma
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Re: 100 mm ?
Reply #7 - 10/10/12 at 14:10:24

Yes, the 1-1.5 mm cylinder wall is getting pretty thin, but all except the very bottom is supported by metal. The lowest portion of the cylinder liner that hangs below the aluminum portion of the cylinder is where the piston is moving the slowest and has the least pressure applied to it.
Will the side thrust on the piston from the crank/rod as it moves before pushing the piston back up be enough to pull the liner wall apart ? ?
Not sure.
But I'm going to find out.
The machinist at a large NAPA shop here thought it just might work.

I've got an old cylinder that can be bored and used for the test subject.

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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10604 Oklahoma Gender:	Re: 100 mm ? Reply #8 - 10/10/12 at 14:13:51 Dave wrote on 10/10/12 at 12:25:25: 738 cc of ground pounding super thumping....Vrroom, Vroom.....Crunch! Dang! Cylinder volume is enough for any manufacturer to call an engine this size a "750".
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greenmonster Senior Member Offline Hellooooo Nurse! Posts: 420 Vancouver BC Gender:	Re: 100 mm ? Reply #9 - 10/10/12 at 16:38:48 It's been a while since I ripped my engine apart so I don't remember this really well, but is there any room at the bottom of the cylinder liner to put a supportive backing behind it?
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Oldfeller--FSO Serious Thumper ModSquad Offline Hobby is now "concentrated neuropany" Posts: 12638 Fayetteville, NC Gender:	Re: 100 mm ? Reply #10 - 10/10/12 at 17:38:30 Nope, As a matter of fact, if you wanted to go larger in the bore you'd have to re-sleeve and you'd have to machine more clearance in the round opening in the cases to do that. And you'd have to increase the cut-away in the sleeve to keep the counter balancer mass from hitting the bigger sleeve. None of which are simple, easy or cheap.
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ralfyguy Serious Thumper Offline Posts: 932	Re: 100 mm ? Reply #11 - 10/11/12 at 16:48:09 What about the overall balancing of the piston versus counterweight and crankshaft? Will it vibrate itself to death?
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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10604 Oklahoma Gender:	Re: 100 mm ? Reply #12 - 10/11/12 at 17:19:19 ralfyguy wrote on 10/11/12 at 16:48:09: What about the overall balancing of the piston versus counterweight and crankshaft? Will it vibrate itself to death? The weight of the piston is close to stock
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ZAR Serious Thumper Offline Rock this town! Rock it inside out! Posts: 961 Kentucky, USA Gender:	Re: 100 mm ? Reply #13 - 10/11/12 at 19:48:02 Quoting OldFeller "None of which is simple,easy or cheap". Gee OF, if we wanted that we'd be driving a Chevette or a Pinto! Or whatever the modern version of those are!
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justin_o_guy2

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Re: 100 mm ?
Reply #14 - 10/12/12 at 05:50:43

LANCER wrote on 10/11/12 at 17:19:19:

ralfyguy wrote on 10/11/12 at 16:48:09:

What about the overall balancing of the piston versus counterweight and crankshaft? Will it vibrate itself to death?

The weight of the piston is close to stock

Has anyone ever decided how close the counterbalance weight is to actual piston weight? I thot I saw something a few years ago where someone had come to the conclusion that the counterbalance was maybe a little heavier that it had to be to do the job. Tho, I gotta admit, If I was buildin an engine, Id go a little lite there, instead of heavy,& I have a hard time believing theyd unnecessarily increase the rotating mass,, hmm,, well,, IDK,, it IS a Big Single, Thats something only a case splittin moment is gonna answer..

Sure would be a hoot to get a few of us together with an engine on a table & take that thing apart..

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