Flash 9: Sanity Restored

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Wheelman-111
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Flash 9: Sanity Restored

Post by Wheelman-111 » Sun May 24, 2015 12:59 am

Greetings:

Fire-breathing, 75-MPH Flash 7 proved just a little TOO hot for civilized Country-Club riding with Ms. Wheel-Person astride. No problem baby, I'll just score a nice wholesome stock engine and tone things down a tad. This too she rejected as just a little too gutless. The porridge is too hot, then too cold... What we need is Just Right.

She still wanted the quiet, "sleeper" look but a bit more Torque on take-off. One pleasant Saturday garage session for Wheelman later and here it is:
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
Still Seeking Red PCX-150
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox, Carb and Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 99KPH

:coolcruise:

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Wheelman-111
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Re: Flash 9: Sanity Restored

Post by Wheelman-111 » Sun May 24, 2015 1:33 am

Greetings:

After removing Flash 8 from the 2001 crankcase supplied by a Forumista with well-deserved respect, I ran into some snags. I installed the piston as usual, but as I dropped the Polini cylinder into place, I couldn't get the headbolts lined up properly to thread. Thinking the gasket was cut wrong, I "ovaled" the holes, but still no-go. Finally (and Lord knows I really hate doing things twice...) I removed the piston again and Dry-Fitted the cylinder to surmise that the larger 47 mm bore's skirts were fouling the crankcase.
F9ContestaContactAnot.jpg
F9ContestaContactAnot.jpg (123.9 KiB) Viewed 4941 times
That'swhy it wouldn't line up. Removing the cylinder yet again, I could see how the thing fouled the curve around the transfer port:
F9CaseMarksAnot.jpg
F9CaseMarksAnot.jpg (227.82 KiB) Viewed 4941 times
The contact pushed the whole cylinder to the left, and far enough so that the bolts couldn't line up. Not wishing to split the cases to carve on them, I just resolved the issue the same way the previous owner appears to have done:
F8F9CornersRzAnot.jpg
F8F9CornersRzAnot.jpg (267.82 KiB) Viewed 4941 times
With the cylinder lying flat and flush on the crankcases, (and the headbolts threading in without issues...) It was time to re-do the cylinder installation from the Piston on up.
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
Still Seeking Red PCX-150
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox, Carb and Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 99KPH

:coolcruise:

curtis966
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Re: Flash 9: Sanity Restored

Post by curtis966 » Sun May 24, 2015 1:52 am

That's odd. I don't think I've ever seen or heard of a cylinder under 50mm not being bolt on especially an Italian.
86 Aero 50,Polini 65cc BBK,malossi oring head,100 oct. 32:1
21mm OKO,Malossi Wild Lion exhaust,
Stock Ruck vari, malossi special belt,1.5k shoes,1k center,
aftermarket bell, front/rear metro wheels, TT vapor,
5in stretch on motor mount,280mm Shock.

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Wheelman-111
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Re: Flash 9: Sanity Restored

Post by Wheelman-111 » Sun May 24, 2015 1:59 am

Greetings:

Cylinder preparation included a generous slathering of Motul Synthetic:
F9CylPrep_resized.jpg
F9CylPrep_resized.jpg (165.34 KiB) Viewed 4937 times
Yeah, this is a first for me too. I can't help wondering if the crankcase is atypical somehow...
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
Still Seeking Red PCX-150
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox, Carb and Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 99KPH

:coolcruise:

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Wheelman-111
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Re: Flash 9: Sanity Restored

Post by Wheelman-111 » Sun May 24, 2015 2:02 am

Greetings:

So what're we gaining here? A 6mm increase in diameter doesn't sound like much, but it's actually a 45% displacement increase. It's starkly apparent here:
F9UnderF8_resized_1.jpg
F9UnderF8_resized_1.jpg (153.49 KiB) Viewed 4936 times
On top of that is the Polini Porting Wizardry, albeit tuned for low-end torque here. The piston appeared to go a hair below the transfer ports and the exhaust port at BDC,
F0BDC_resized.jpg
F0BDC_resized.jpg (163.13 KiB) Viewed 4936 times
and left a little squish at TDC:
F9TDC_resized.jpg
F9TDC_resized.jpg (141.75 KiB) Viewed 4936 times
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
Still Seeking Red PCX-150
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox, Carb and Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 99KPH

:coolcruise:

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Re: Flash 9: Sanity Restored

Post by Wheelman-111 » Sun May 24, 2015 2:27 am

Greetings:

It's an Iron Contesta, packed in Gin-You-Whine Polini carton wrapped witta-da Polini tape. It really doesn't seem like a knock-off, and I've bought at least 2 before. My suspicion is that my 2001 "Honda" crankcase might have been part Sym... The fact that the stock Honda cylinder needed to be carved too is a Clue.

A word on Piston installation:
F9Clips_resized.jpg
F9Clips_resized.jpg (126.73 KiB) Viewed 4932 times
Seems easy enough, but I recommend you keep a pristine set of quality needle-nose pliers swaddled in oil-soaked cheesecloth for this occasion. Do NOT use the ones you use to pull out errant nose hairs.
F9Clips_resized.jpg
F9Clips_resized.jpg (126.73 KiB) Viewed 4932 times
Read the caption. Read it again. Be gentle with these spring clips. Don't stretch them beyond their elasticity. Dozens of posts over the years confirming the disastrous consequences of a circlip popping out. On the Polini-style clips, the "legs" must point up or down with respect to the piston. That thing is hammering over 100 times a second, so a clip on its side just might have the momentum to work loose.

Another potential Snag with this build:
F9Compr160_resized.jpg
F9Compr160_resized.jpg (165.68 KiB) Viewed 4932 times
Good thing I've got 50% AvGas in the tank. Is there a risk if I run Premium - or rather Ms. Wheelperson does?
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
Still Seeking Red PCX-150
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox, Carb and Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 99KPH

:coolcruise:

1man8scoots
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Re: Flash 9: Sanity Restored

Post by 1man8scoots » Sun May 24, 2015 2:28 am

I got the contessa from you, and he from me.
It sounds like the deck of the engine is lower some how. This for certain I've never removed the cylinder and the guy I got it from really didn't seem too mechanically or intellectually inclined.
So odd. I wonder how many other blocks are like it. In order for it to leave the factory they would have had to cut it at the factory. When they tried to bolt it down from the factory someone had to say, "hey boss it don't fit?". Maybe ask honda about this oddity? Your 01 block I received did you have to shave any skirts?

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Wheelman-111
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Re: Flash 9: Sanity Restored

Post by Wheelman-111 » Sun May 24, 2015 2:35 am

Greetings:

Everything I bolted onto that case was unshaved except the Fabrizi, which needed the piston "corners" knocked down. That block saw a Nikasil 78, Corsa, Malossi Iron and MHR - none of them needed shaving of anything. Weird.
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
Still Seeking Red PCX-150
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox, Carb and Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 99KPH

:coolcruise:

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ped
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Re: Flash 9: Sanity Restored

Post by ped » Sun May 24, 2015 2:45 am

Hi wheelman.
it looks like the cylinder head bolt holes are off a little. I wonder if it would restrict the transfers?
I was looking at my corsa to make a comparison.
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Life's a trip enjoy the ride.
94 elite SR, 86 spreedio, polini corsa, keli variator, 8.4, jet. speed 65 mph
spreedio video. https://www.youtube.com/watch?v=BZr46_-douQ

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Re: Flash 9: Sanity Restored

Post by Wheelman-111 » Sun May 24, 2015 2:50 am

Greetings:

Thanks, Ped. Off, how do you mean?
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
Still Seeking Red PCX-150
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox, Carb and Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 99KPH

:coolcruise:

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ped
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Re: Flash 9: Sanity Restored

Post by ped » Sun May 24, 2015 3:01 am

Wheelman-111 wrote:Greetings:

Thanks, Ped. Off, how do you mean?
take a look at the photo with the dremel. you can see the bolt holes on the bottom. one side is closer to the transfer, the other one has more meat. the bottom holes look offset.
There may be blockage to the transfers? it won't sit centered on the block. :imo:
Last edited by ped on Sun May 24, 2015 3:29 am, edited 3 times in total.
Life's a trip enjoy the ride.
94 elite SR, 86 spreedio, polini corsa, keli variator, 8.4, jet. speed 65 mph
spreedio video. https://www.youtube.com/watch?v=BZr46_-douQ

1man8scoots
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Re: Flash 9: Sanity Restored

Post by 1man8scoots » Sun May 24, 2015 3:12 am

Corsa vs contessa.

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ped
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Re: Flash 9: Sanity Restored

Post by ped » Sun May 24, 2015 3:17 am

1man8scoots wrote:Corsa vs contessa.
ooh I see. good point 1man.

Wheelman, keep that dremel handy. :wink:
Life's a trip enjoy the ride.
94 elite SR, 86 spreedio, polini corsa, keli variator, 8.4, jet. speed 65 mph
spreedio video. https://www.youtube.com/watch?v=BZr46_-douQ

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ped
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Re: Flash 9: Sanity Restored

Post by ped » Sun May 24, 2015 3:47 am

ped wrote:
1man8scoots wrote:Corsa vs contessa.
ooh I see. good point 1man.

Wheelman, keep that dremel handy. :wink:
:peace:
Life's a trip enjoy the ride.
94 elite SR, 86 spreedio, polini corsa, keli variator, 8.4, jet. speed 65 mph
spreedio video. https://www.youtube.com/watch?v=BZr46_-douQ

1man8scoots
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Re: Flash 9: Sanity Restored

Post by 1man8scoots » Sun May 24, 2015 1:38 pm

Block has not ever been decked or sanded down. This is a 350 mile engine that has never been opened up. Just like Johnny248 engine honda had some quality issues with these blocks.

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