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Old 07-18-2014, 11:51 PM   #1
Mudguts OP
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Joined: Jan 2006
Location: Some were in , lostralia
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Rally engine's & exhaust systems

Ok we have the Nav tower thread , the ICO thread so here's the engine thread
For tips and rebuild tricks

So my set up is this

KTM 690. (654cc) bone stock : well motor has not been molested as yet
Vortex X10 programable ignition
Andrea Dionda Rally exhaust 50mm through to 60mm at muffler link pipe
Muffler Akro rally. 60mm taper core down to 50 mm at exit

So my bike goes Ok but I also know that the exhaust is to big for my current set up . Im in planing of building a big bore engine in other words saving $$$$ for the parts

1) 2012 stroker crank
2) port & polish head
3) Cam stock ,Rally , DukeR ????
For the piston there are a few chooses
Stock 102mm 11.8:1 Compression Ratio
Hi Comp 102 12.5:1 CR
Then I can go 103 ,104,105mm piston , but may have to swap over to carb'd and $$$$.

I'm leaning towards stock size piston for ease of sourcing and reliability but also want a torque monster that can wheel stand at 100kph in 4th
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Old 07-19-2014, 06:22 AM   #2
Mad Cow
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I'm of the opposite opinion, go standard for maximum parts availability.

My 450 has an entirely standard engine.....

Including a "standard" 525 barrel and piston
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Old 07-20-2014, 06:01 AM   #3
michael1968
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Quote:
Originally Posted by Mudguts View Post
1) 2012 stroker crank
2) port & polish head
3) Cam stock ,Rally , DukeR ????
For the piston there are a few chooses
Stock 102mm 11.8:1 Compression Ratio
Hi Comp 102 12.5:1 CR
Then I can go 103 ,104,105mm piston , but may have to swap over to carb'd and $$$$.

I'm leaning towards stock size piston for ease of sourcing and reliability but also want a torque monster that can wheel stand at 100kph in 4th
Stick size piston is good because you don't need to worry about getting your barrel bored out and the potential issues associated with that (sleeves failing, cooling etc.).

You probably know but you don't want to polish your intake ports, the slightly rough surface keep your fuel from forming big drops.

Another good few hp out of a 690 and you'll have a real weapon!
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Old 07-20-2014, 05:08 PM   #4
Mudguts OP
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Quote:
Originally Posted by michael1968 View Post
Stick size piston is good because you don't need to worry about getting your barrel bored out and the potential issues associated with that (sleeves failing, cooling etc.).

You probably know but you don't want to polish your intake ports, the slightly rough surface keep your fuel from forming big drops.

Another good few hp out of a 690 and you'll have a real weapon!
Defiantly new more torque to lug my fat ass around , but had a win out playing with the fuel trims on Saturday
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Old 07-22-2014, 07:22 PM   #5
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Just had Crazy idea of a twin cam head for the 690 I think it would be a good way to throw away $$$$$$$$ .
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Old 07-22-2014, 10:16 PM   #6
craigincali
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if you want to spend cash I will give you my paypal account and you can put it in there.
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Old 07-24-2014, 11:32 AM   #7
JMo (& piglet)
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Rally Raid Products have just introduced a hi-comp piston for the stock bore... that would be a good place to start?

Jx
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Old 07-25-2014, 11:33 PM   #8
Mudguts OP
when in doubt GAS IT
 
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Originally Posted by JMo (& piglet) View Post
Rally Raid Products have just introduced a hi-comp piston for the stock bore... that would be a good place to start?

Jx
I'm keeping an eye on john's and martins FB web sites just in case they post some dyno runs with the new pistons
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Old 07-25-2014, 11:55 PM   #9
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Originally Posted by Mudguts View Post
I'm keeping an eye on john's and martins FB web sites just in case they post some dyno runs with the new pistons
I'll mention it to them - I know that Martin has his own 'demo' 690 EVO2 set up now, so perhaps the new HC piston will find its way in there soon!

Jx
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Old 07-29-2014, 03:35 PM   #10
Seth S
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Quote:
Originally Posted by Mudguts View Post
Just had Crazy idea of a twin cam head for the 690 I think it would be a good way to throw away $$$$$$$$ .
Ditch the cams and go with solenoids
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Old 07-29-2014, 08:31 PM   #11
Mudguts OP
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Trying to keep the electrical simple
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Old 07-31-2014, 05:33 PM   #12
Seth S
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Well lets see..

My current engine is running stock rods with offset bushed flat top vw piston. The 16v head is fitted with double valve springs, rally cams, solid lifters, and bigger volvo valves. Alumiunum flywheel at the moment and likely a quartermaster clutch. Header is a 4 into 2 into 1 header. Custom ITB intake and T5 fuel injection. Possibly an electric water pump and more compact denso alternator.
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Old 08-01-2014, 01:29 AM   #13
Mudguts OP
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And it's got four wheels Pppfft , traction junkie
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Old 08-01-2014, 08:14 AM   #14
JayBo1
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Quote:
Originally Posted by Seth S View Post
Well lets see..

My current engine is running stock rods with offset bushed flat top vw piston. The 16v head is fitted with double valve springs, rally cams, solid lifters, and bigger volvo valves. Alumiunum flywheel at the moment and likely a quartermaster clutch. Header is a 4 into 2 into 1 header. Custom ITB intake and T5 fuel injection. Possibly an electric water pump and more compact denso alternator.
Yeah, but does it's wheels fit between the rails of a stock grate?
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Old 08-01-2014, 01:18 PM   #15
Seth S
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Originally Posted by JayBo1 View Post
Yeah, but does it's wheels fit between the rails of a stock grate?
Not when it's airborne
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