Ported Big Bore Top End Installation

THE BANSHEE ZONE

OK, time to put the big bore engine back together. First step is to clean the case gasket surface for any traces of the old base gasket. The Vito's 404 kit comes with a one piece, port matched base gasket.

Now install the piston rings on the Power Pistons. The ring end gap must be lined up with the notch in the piston. Note both ring end gaps are positioned directly over the intake port windows on the piston.

This top end install will be performed differently than the original "top end rebuild" page found here at The Banshee Zone. The original top end rebuild the pistons were attached to the connecting rods, then the cylinders were slid down over the pistons and bolted in place. This time I'll be inserting the pistons into the cylinders first, then I'll attach the cylinder\piston combo to the connecting rods. The main advantage of installing the pistons into the cylinders first is the ease of compressing the piston rings and maintaining the rings don't spin out of position. Here's how its done...... starting with the right\clutch side cylinder\piston. Flip the cylinder upside down. Insert the INSIDE piston pin circlip into the piston. Now.... with the piston rings and the "inside" piston pin circlip installed, insert the piston into the bottom of the cylinder, compress the 2 piston rings and make sure they don't spin from their marks on the piston. Once the piston is installed past both piston rings, gently flip the cylinder over and make sure the arrow etched in the piston dome is facing towards the front of the engine towards the exhaust pipes. Double check the arrow on top of the piston is facing forward !!

In this photo you can see the piston rings are aligned with the notches in the piston.

Here you can see how far the piston should be inserted.

Now take your piston\jugg assembly and put it on the connecting rod. Insert your piston pin and then the piston pin circlip. Stuff rags around the open crankshaft to prevent the pin circlip from accidentally falling into the case.

Make sure both piston pin circlips are seated correctly and slide the cylinder in place on the studs.

Now repeat the whole procedure for the other cylinder.

OK, now were cookin !! The head is bolted on to the juggs and rear coolant hose is hooked up. New stainless steel head and base nuts holds the new engine together. The head and base nuts are tightened in the correct sequence and gradually tightened to 20 ft-lbs.

Couple more hoses and spark plug wires attached. New V-Force reed cages were added along with new intake boots. The boost bottle and the carbs are in place. One exhaust pipe is on.

Here's the finished new engine. Its ready to rip.

BILL ADAMS PORTED AND POLISHED
404 BIG BORE

Finished. Watch for the upcoming Delta V-Force page and the pages dedicated to riding the ported 404.

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Ported Big Bore Top End Installation


	THE BANSHEE ZONE Ported Big Bore Top End Installation OK, time to put the big bore engine back together. First step is to clean the case gasket surface for any traces of the old base gasket. The Vito's 404 kit comes with a one piece, port matched base gasket. Now install the piston rings on the Power Pistons. The ring end gap must be lined up with the notch in the piston. Note both ring end gaps are positioned directly over the intake port windows on the piston. This top end install will be performed differently than the original "top end rebuild" page found here at The Banshee Zone. The original top end rebuild the pistons were attached to the connecting rods, then the cylinders were slid down over the pistons and bolted in place. This time I'll be inserting the pistons into the cylinders first, then I'll attach the cylinder\piston combo to the connecting rods. The main advantage of installing the pistons into the cylinders first is the ease of compressing the piston rings and maintaining the rings don't spin out of position. Here's how its done...... starting with the right\clutch side cylinder\piston. Flip the cylinder upside down. Insert the INSIDE piston pin circlip into the piston. Now.... with the piston rings and the "inside" piston pin circlip installed, insert the piston into the bottom of the cylinder, compress the 2 piston rings and make sure they don't spin from their marks on the piston. Once the piston is installed past both piston rings, gently flip the cylinder over and make sure the arrow etched in the piston dome is facing towards the front of the engine towards the exhaust pipes. Double check the arrow on top of the piston is facing forward !! In this photo you can see the piston rings are aligned with the notches in the piston. Here you can see how far the piston should be inserted. Now take your piston\jugg assembly and put it on the connecting rod. Insert your piston pin and then the piston pin circlip. Stuff rags around the open crankshaft to prevent the pin circlip from accidentally falling into the case. Make sure both piston pin circlips are seated correctly and slide the cylinder in place on the studs. Now repeat the whole procedure for the other cylinder. OK, now were cookin !! The head is bolted on to the juggs and rear coolant hose is hooked up. New stainless steel head and base nuts holds the new engine together. The head and base nuts are tightened in the correct sequence and gradually tightened to 20 ft-lbs. Couple more hoses and spark plug wires attached. New V-Force reed cages were added along with new intake boots. The boost bottle and the carbs are in place. One exhaust pipe is on. Here's the finished new engine. Its ready to rip. Finished. Watch for the upcoming Delta V-Force page and the pages dedicated to riding the ported 404. Home TBZ Website Updates \| Banshee Zone Board \| SIGN THE GUEST BOOK \| Top End Rebuild \| Bottom End Rebuild \| Transmission Pics \| Kick starter Related \| Clutch and Stator \| General Specs \| Torque Specs \| Carburetor Specs \| Pilot Jet Page \| Air Screws Page \| Needle Jet \| Main Jet Page \| Cool Head Compression Chart \| V.I.N. Chart \| Cylinder Bore Chart \| Banshee Zone Color Scheme Chart \| Premix Chart \| Banshee Zone Gallery Page 1 \| Banshee Zone Gallery Page 2 \| Banshee Zone Gallery Page 3 \| Banshee Zone Gallery Page 4 \| Banshee Zone Gallery Page 5 \| Banshee Zone Gallery Page 6 \| Banshee Zone Gallery Page 7 \| Banshee Zone Gallery Page 8 \| ATV Links \| ATV Logos \| Vote For The Banshee Zone \| Banshee Web Poll \| BLUETRAXX.COM Yamaha Chat Room \| Maier Radiator Cover \| Toomey 2:1 Air Filter System \| JL Billet Kick Starter \| Hinson Billet Brake Pedal \| Pro-Taper Handlebars \| Vito's 404 Big Bore + A/R Porting \| Ported Big Bore Top End Installation \| CPI PIPE PICTURES \| FMF FATTY PIPE PICTURES \| PAUL TURNER PIPE PICTURES \| PRO CIRCUIT PIPE PICTURES \| TOOMEY T-5 PIPE PICTURES \| Banshee Parts Microfiche \| Front Brake Pad Installation \| Rear Brake Pad Installation \| Repacking Your Aftermarket Silencers \| Ignition Timing \| My Banshee \| The Strippins \| Lots Of Banshee Pictures Ported Big Bore Top End Installation