How To: Daddog Changing Engine Piston

[Woody_393]

PAGE DOWN TO GET TO THE SOON TO COME VIDEOS, THIS IS JUST THE STORY OF THE DOGRIDER MOTOR

Ok, so we have been busy as can be getting testing ready, and have received enough requests that we put up the video early. Here is a 480 cc DO IT YOURSELF motor for around 500 bucks.

Just follow the videos on how to remove the head part, send the cylinder in to have it bored to 99.01 mm by millenium or just have our builder do it.

Tell him the dogriders sent you, and he will know exactly what you want. Porting is available also if you dont want to port it yourself.

Anyway, by following these vids you can pull apart your motor and send in the cylinder in to get it bored and plated. With the phone number on the site, he can order the 99mm pistons which are in stock. When it comes back, bolt it together for your new 480 motor.

Our next step will include a 4 mm stroker crank, to take you to a dogrider 508 mm displacement!

This first step should be a nice 480 cc motor with a touch more power than the 470's out there.

Drawbacks?
It may overheat, but we will have to see. You might want to buy a bigger radiator.

Also, the two ring piston that is supplied from our builder will need a ring change more frequently than the stock three ring piston... - just do it yourself.

Watch the vids. Get a repair manual. The replacement should not be a problem if you can do the engine work yourself, with the videos, right?

What else are you going to do when it rains? If you dont feel like wrenching, Just take it the quad to your builder or dealer and give them the instructions and the phone number to get the parts. That way they can order the piston.

No one will go much more than 480 cc as the cylinder wall is pretty maxxed out at this level for bore. There are reports that other riders are happy with it. After we get the 99 mm setup and race it a bit, STEP 2 is a special order Falicon 4 mm stroker that Glen at Falicon is making for us.
We had to special order a longer rod to keep the engine more square and take the load off the piston. So with the 99 bore and the 4mm stroke the REAL FINAL DOGRIDER MOTOR will be a 508! If you use a 470 top end, it will be a 500!

Part two was our invention. After the dogriders, and dog dag had a few late night dog talks about motors and stuff (Mainly while they were doing engine work), we said HEY, WHY NOT make one if it isnt available? WHY AREN't there any 4 mm strokers out there? After much communication, Glen (Falicon man) went over it with us and said it should work great, because we are increasing our rod length the same proportion as the stroke length and the stress on the engine would be lesened due to the rod. It should work very nice... Glen was interested, and believes it will be a nice motor as it keeps the same stroke to rod length ratio as the original motor. If you just shorten the rod to increase the stroke, this changes the motor dynamics, and this stresses the motor and increases acceleration (THIS IS not as good) at TDC and BDcenter.

Glen is ordering a bunch of rods as this longer rod for the YFZ has never been made before by him, and he could not find a blank from another motor in his special book. So it will be specially made. The specs are still in development.

The man who is making the 99's will be making the stroker also. We will give him the dimensions and data so he can make them available also (IF IT WORKS). This will be an expensive test, or a succesful build. Everyone so far thinks it will work, so we have to wait and see.

Stay tuned, should be a fun motor to test. We don't know what it will be like, it could be better or it could be worse.

We will need a completely different chain and add a spacer plate. Also, the engine bolts have to be manufactured.

The timing will be identical for cam and intake/exhaust. That means you can use the stock cams.

We HOPE to have a complete video step by step how to make your own 508, where to get parts how to make the stroker work with a longer rod, etc. Now the bad news is this... the video to be complete, will be too long to put up here!

We are maxxed out on our storage at 400 megabytes, and it costs us more each month, so we know not many people want to build strokers. When we are done, the video in all its parts will be one CD. We will sell them for a fair price, like 20 dollars.

Takes time to burn, package, and mail them. The dogriders would rather go riding than package CD's, so we have to make it worthwhile for them. But, you will be able to see how to do it. Every bolt, every address, everything. So it will still be helpful if you want to do a project. (We haven't started yet), So give us some time, we will let you know. Then we will tell you If it works, and if it DOES NOT WORK, we will tell you, and hopefully someone can improve on it. Finally we WILL get this thing to work so everyone can have a cheap fast good motor. The strokers will be available in two weeks. They arent going to get much bigger than this. Hey, Oh, the BEST part is this! Everyone out there that have 98 mm bores (470's) can put the stroker in and get exactly 500 cc's! Everyone can benefit. I think that is why Glen thought it was a good idea. He will have several rods available in a few days. Send in your crank now if you want to join in the testing/building proocess. We'll call it the BBLUETRAXX and YFZCENTRAL developed community effort. I would love to have these sites get together, joint membership. They are the best out there with different needs being addressed. This engine building effort may get more members for www.bluetraxx.com or www.yfzcentral.com, That is where we hang out and that is where you can get ahold of us, because there is always something happening at these sites, and they have been VERY good to newbies. Please don't start putting up dumb posts, but hang around for a few days to see how they run. Thanks! YFXCENTRL is more for the young at heart, budding racers, how to turn jump, build. If you just bought one that is where to go also. If you are into SAND ALSO and DUNES you have to join bluetraxx.com! Very nice. They are both technical addressed forums for newbies, with builders discussing pros and cons. Both are excellent and fun. (Thats my two cents!)

You want to replace your rings? Check your rings? Replace your piston with a new one or a different one?

You just want a honkin powerful motor? Beyond the power of a 470? (Everyone has one of those)

You wnat to put in a Dogrider BigBore kit? 480cc? We are testing one now, but if you can't wait for the results, here is how to get yours! CALL RIGHT AWAY as because as soon as this page goes up, the shop will be full for a while with orders.

The best way to explain something in my opinion is with videos, then with pictures. I think writing is a necessary chore to get things accomplished, but videos are more fun, that is about it. Give me the pictures.

Anyway, one evening we couldn't ride because it was windy out, and too dark. So the dogriders sat down one saturday night, put on their coveralls on and decided to replace their piston. So we shot this video in the dogrider studio about how to remove pistons in the YFZ-450. (Garage).

IF YOU DID THE CAM MOD OR SAW THE VIDEOS, THIS STUFF IS NOT MUCH MORE COMPLICATED, SOON YOU WILL BE ABLE to do most of these things.

There are 3 videos in order, and just watch 1 through 3 to see how the dogriders are learning to do basic engine work.

[Woody_393]

1. TAKING OFF THE HEAD (9 MB !!! )

You will now send the head in to a company to have it bored to proper dimensions, if you wish, or leave it stock, depending on the piston you wish to install. We are testing a bigger bore kit that is bored to 99 mm diameter. So the cylinder was sent out to have a 99.01 mm bore put on it and re nikalsilled.

If you rebore it, you have to get the right size piston for the bore. Otherwise the piston will rattle around and break many things. You can have your local engine shop do this, or you can order a stock diameter GYT R piston. We are selling 99 mm pistons with a 13:1 compression ratio. Our phone number is 1-608-224-2524

(You will need to run alcohol or race gas with it). You also need to buy a 99 mm head gasket. This company will bore it to 99 mm, sell you a piston and a gasket, and you just put it back together. The price for the boring and piston is around 500 dollars total. ASK FOR WILL and tell him the DOGRIDERS sent you so he knows what to do for you. Tell him you have a YFZ 450 Quad, and that you want the 99 mm cylinder kit and piston and gasket too. (Dont forget the gasket). We had a special 99 mm piston 11 to 1 made that will let you run pump gas. Why 11 to one? Because once the STROKER is put in, the compression will be 12.1 to 1 due to the extra volume. Write us at daddogrider@yahoo.com if you are interested in placing an order for one. We have two for sale now. They are arriving in 12 days or so.

This 11 to one will allow you to run gasoline NOW, and still give you 12 to one once you upgrade to the stroker. You can run Supreme in your new motor. once the stroker is in place. We are selling them for 225 plus shipping as they are more expensive because they are a special order. We will get the piston perfected on the second or third batch.

Anyway, here is how to install your kit for now (the 480 kit). It was shot for stock piston, but the mechanics are the same, except the piston will have two rings instead of three.

2. REMOVING THE PISTON (5 MB )

3. REPLACING THE PISTON (9 MB !!)

4. REPLACING THE CYLINDER WALL 3 MB