My reincarnated 5-speed ported barrel.

[sanjaymugur]

set up on my bike
-> 4-speed 2002 model,
-> 90/100w nippon electrical kit with RXG internal pulsar coil measuring 76 ohms,
-> 5-speed carb, 4-speed reed block( 5 speed has a different reed block),
-> 5-speed bore head(high compression)
-> 5-speed grey CAT con,
-> Chinoy Filter filter,
-> 16" (3.25*16) Yezdi wheel at the back, seat secura M86 3.00*18 wheel at front.
-> 4-speed sprocketing ( 16/34 )
-> RDD CDI, timing is still stock , will advanced it once i get the original plate.
-> bosch super-4 spark plug with 6.2 mm spacer

the 5 speed bore was ported by famous Chenai tuner... was not behaving properly..total crap..worse than my local mechanic ported 4-speed barrel... so, enquired Mr Chinoy if he can revive the barrel, he agreed for stage-2 porting....

how is it now ?
on recieving the barrel i could see lot of metal removed, exhaust port looked shiny like a glass, inlet was also touched upon...

with 165 jets on 5-speed carb with needle in middle position, bike was pulling really well in 3rd & 4th gear but had lot of vibrations.. also, b'cas of being too rich it was misfiring often... top speed attained at that time was 117 -118 as shown by enticer speedo meter

changed the jets to 135 & needle position to the richest. bike breathed a lot better in this setup.. was moving good & it had better top end i guess(i have removed speedo meter now).. but felt lot lean at higher speeds when jets came into picture...
Mr Chinoy drove in this setup & said your bike is pretty much dialed in...

did not want to run lean at high speeds & hence got 150 jets.. needle in middle position & bike is back to pulling well on 3rd & 4th gear..

now bike has lot less vibrations..the only big issue is bike is just not holding the torque... need to time the bike properly & try the 140 & 145 jets...

have not checked the mileage

overall pleased with the setup, still not jumping with joy....

thanks Mr Chinoy for taking up the work.. if only you had taken the job earlier !!!!!!

will keep updating here after timing & jetting it properly. & 5 speed sprocketing ( 16/38 ).

[chinoy]

Well some people have to learn the hard way.
If your pulsar is in stock position then what will happen is you will find the power is good in the low and mid but in the higer RPMs it will feel soft cause it is retarding the timing too much.

In such cases a stock CDI would be your best option.You will really like it.
If you can set the timing or advance it by a few degrees say 3-4 then your top end will be much stronger.

Not bad for a cat con bike.

[sanjaymugur]

Not bad for a cat con bike.

will rephrase this statement to -> "CAT CON is not bad for the bike" ...

If your pulsar is in stock position then what will happen is you will find the power is good in the low and mid but in the higer RPMs it will feel soft cause it is retarding the timing too much.

ok thats what you were saying about the look up table & subtracting of timing depending on RPM..... so if i advance the timing i should get both the low end power & timing wont be retarded too much at high rev... thats killing 2 birds in one shot...

will try stock CDI with existing pulsar coil setup

[chinoy]

Actually a better thing would be keep the digital cause it has twice the spark stength.
Just chose the static full advance option.

Timing will be same as stock but you still have power from the increased burn and reduced Ingition delay.

[chinoy]

Here is something to remind you and to think about each time the gas goes out your exhaust.

A lot of people have mailed me asking about how I fixed the barrel, pictures of before and after etc.

Posting pics of before would be unethical and rude to a fellow tuner.
Posting pics after I also dont belive in.

How it was fixed. ?

How I got it.

1. Exhaust duration had been increased quite a bit.
2. Inlet port untouched.
3. Transfers untouched except for very minor touch at entry.

WHat we did.

1. Matched the trasfer duration to the increased Exhaust port duration.
2. Extencive work on the transfer passageways to improve flow.
3. Extencive work on the inlet to increase flow and remove all casting imprefections.
4. Moded the head to match the increased Ex. duration.
5. We did not increase the exhaust duration any more. As the customer was looking for a peppy street bike.

Arround 120 for a cat con bike and a customer who feels he got something that runs and is faster than what he had before is all one can wish for.

Earlier problems of the setup not runing. I dont think it was a jeting or a timing issue.

If the job had come to me first.
I would not have reaised the ex. duration we would have done a combo between the 4 speed and the 5 speed.
Just like we do on the LTs.
But I got a ported barrel. So the only way forward was to make what we had run well.

[chinoy]

One issue that keeps croping up into my mind.
ANd no its not about the cat con.
Thats your pet peve and hang up. Ive allready explained the issue of flow that you will have with a cat con. You cant have a rever and a cat con.

But what I dont understand is You and I both agree the digitial CDI setup right with the right timing works better.

Then why arent you runing that setup ?
Why the digital CDI with the wrong timing ?
Ok some long story about the plate going missing in chenai.

Then dont judge the setup till you get at least the basics like timing right.
Ive told you bring the bike to me I will get it timed at Adus place.

But you want the 100 watt head light with the 3 pole lighting, the lighter drum but not the right timing.

You need to set the priorites for the bike right.
Im still not too bothered.
We are faster than your earlier setup.
And untill a cat con bike goes faster than yours Im not reall sweating it.
In fact after you sort out your timing we should do a land speed run for cat con bikes.

[cbr1000f]

Edit your first post sanjay,there's supposed to be no name taking on this forum.

[sanjaymugur]

haaaa..., remember that picture when i got the barrel from you... too good...

brass plate or an aluminium plate is on the way for holding that 90/100w coil as it is supposed to be, might take 2-5 days.. will come to your place once installed to check what is the timing with the plate.. will take just 30 mins of your time.. now i can remove the magnet cover & put it back along with gear lever.. some day will remove & put the barrel as well..

had tried the stock CDI, timing was totally off , bike was starting & stopping changed it back to RDD CDI in less than an hour.

[sanjaymugur]

But what I dont understand is You and I both agree the digitial CDI setup right with the right timing works better.

Then why arent you runing that setup ?
Why the digital CDI with the wrong timing ?

plate is the only issue.. i should be getting it ,
else will drill holes around the entire circumference of the plate with some gaps & will keep moving plate till timing is setup properly.. worst case will buy a new one with just magnet & coil ie.90/100w electrical kit, no rectifier...

Digital RDD CDI always.. there is no 2nd thought about it.. even today it is my number UNO investment on bike.. rest just comes a distant 2nd...

give me some time.. i will set the timing exactly at what the RDD CDI requires..

[sanjaymugur]

Then dont judge the setup till you get at least the basics like timing right.
Ive told you bring the bike to me I will get it timed at Adus place.

You need to set the priorites for the bike right.
Im still not too bothered.
We are faster than your earlier setup.
And untill a cat con bike goes faster than yours Im not reall sweating it.
In fact after you sort out your timing we should do a land speed run for cat con bikes.

i have been telling you that & i have mentioned in my earlier post also that i will not be giving feedback until timing is set right. but you were in a hurry for me to put up the feedback.....anyways getting the job done is more important..

timing is first then jetting & then update the feedback...

[chinoy]

1. CBR is right no name taking better take off the name. I am in agrement on this.

2. You are right. It was my fault for rushing you. SHould wait till you get the basics right. My excuse it was taking to long and I felt we achived something by geting the barrel to run so well. Even without the right timing or jeting.

3. We really shouldnt be bothered about top speed.
Ive built RXGs that do 145. Let me tell you they are a bitch to ride. And the fun factor is very very small. Anybody who has riden cut cranks old bike can confirm this.

My aproach to engine design is undergoing a radical change with the evolution of my new RD. And I suspect this new direction is going to be a big hit.
I now figured out what you wanted. And its basiclly a good combo setup.
Nothing beats the combo. In terms of dirving pleasure.

My only request is that you do the pending jobs ASAP. Otherwise people will judge the job on what they see. They arent intrested in the details.

[sanjaymugur]

i am not able to acess edit button on that post, admin can edit my post.. no probs...

combo setup always...

will get the timing right. will check with your timing gun & then 1 or 2, 50km, test rides & update feedback..

[chinoy]

Id still like to see the bike run at least once without the cat con.
Im all for sticking to the cat con if you like it.
As long as its the fastest Cat con RXG on the road Im cool.

[sanjaymugur]

ok... only after setting the timing properly.....