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T-Bolt USA Tech Data section and PM member submissions

21K views 55 replies 16 participants last post by  T Bolt USA 
#1 ·
Hi , we have a new data base set up for online Tech Data , please review if you have time

TBolt USA, LLC Tech Database - Home



the current sections are some of the simple common and reoccurring questions and tech calls we get every day so this should help



we have more to come but it takes time

a few i would like to add:

how to install/ adjust a clutch cable (dont laugh)

oil filter / clutch maint

how to install a cam

how to adjust you chain



if any PM member would like to add anything we would be interested in your input

thanks

vince
 
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#27 ·
Re: Tech Data section and PM member submissions

Here is the link to PP / ZS 160 HO Engine Parts Breakdown



PITSTER 150 HO ENGINE BREAKDOWN



Big Thanks to Panic Grip Designs
 
#29 ·
Re: Tech Data section and PM member submissions

Images provided by warpig0470 - THANK YOU !



IMPORTANT



Pit Bike Engines with Bottom Oil cooler connections MUST run oil cooler or jumper the 2 oil cooler connection points



Engine damage WILL occure if this is not done



PLEASE See these pictures for how to connect the oil cooler















 
#30 ·
Re: Tech Data section and PM member submissions

Pit bike Engine sizing for Kits

http://www.tboltusa.com/Tech_Data/index.php



There are quite a few Pit Bike engine Types



Please determine a few key factors.

This will help narrow it down to what will actually work



1)Front clutch on crank,or rear clutch on tranny main shaft



2)Stud pattern honda 50 or larger Lifan GPX type



3)63mm,69mm,78mm,81mm or other cylinder.



4)piston wrist pin size 13mm,14mm or 15mm.



5)Spigot hole or case hole inside diameter



6)Can sprocket tooth count 28T or 32T tooth are common











 
#31 ·
Re: Tech Data section and PM member submissions

When installing Pit Bike engines you may run into different types of exhaust pipes and head ports.



1) Honda type 6mm stud w/ angle "A"



2)KLX type 8mm stud w/ angle "B"



The two types are at only a slightly different angle.

they don't directly interchange but are so close that they can be made to fit

buy various means.



Helpful items:



1) NCC Pipe Adapter

This is used for adapting Honda type pipes to KLX type heads.

Just pull the 8mm studs from the KLX head and install the new 6mm adapter studs.

Then the offset collar is inserted into the head port and rotated to fill the gap.







2)Copper Exhaust gaskets.

Using 2-3 Crush-able exhaust gaskets in a stack can take up the gap.



 
#32 ·
Re: Tech Data section and PM member submissions

Pod filter sizing:

Measure in OD of the Filter end of the carb to find out the size.

In the picture we show a common Pit bike 22mm mikuni.

The OD of the Filter end of the carb is 1.5" or 38mm.



 
#33 ·
#34 ·
Re: Tech Data section and PM member submissions

Check for Proper Ring End Gap

Normally new rings will be fine , but just to be sure.

Failure to ensure proper ring end gap may cause engine damage



Check the end gap by placing the ring into the cylinder

Use the piston to square up the ring in the bore

Check the end gap by using a feeler gage.



Here are KLX110 Specs:



Piston Ring End Gap

Standard: Service Limit:

Top 0.15 0.30 mm 0.6 mm

Second 0.30 0.45 mm 0.8 mm

Oil 0.10 0.60 mm 0.9 mm



 
#35 ·
Pit bikes Heads from YX 150cc / YX 160cc & ZS 155cc will fit on older KLX110 and have Better Cams , Valve sizes and offer performance gains over stock



KLX Cam and Tappet covers fit YX Heads but NOT ZS Heads



YX / ZS Aluminum Cylinders w/ Iron liners can be machined to have smaller skirt OD and also fit KLX110

But are slightly shorter and will require Thicker base gaskets and careful checking of piston to head clearance







For more Tech info:

TBolt USA, LLC
 
#39 ·
Hey I just wanted to bump this thread to say thanks to the guys at tbolt for taking the time to do the the tech section. I used the it to get the wiring straight on a Pitster Pro 140 engine I swapped into my SSR B2. It would have been a struggle without the help.
 
#41 ·
With the help of TB Parts & Panic Grip designs the Tech Data section has been revised and Updated

Recently Danos bike shop Tech info site went down and Many TB Parts Install tips with it.

We Uploaded quite a bit of this now to our Tech Data section

TB Race head install

TB Manual clutch install and more

Mikuni Super Tuning guide



Also

Panic Grip revised it into main categories for ease of use
 
#42 ·
We us an old school trick to fit the kickers and shifters to the spline snugly



At times the pinch bolt wont have enough force to put the proper pressure on to make the shifter/kicker sung



Take the pinch bolt out of the kicker/shifter

put the unit in a bench vise and give it a lil squeeze to close up the gap



Also to open the gap use a 1/4" Standard screwdriver in the slot

Tap it in till the gap open up just enough to slip it over the shaft
 
#45 ·
How to re-install the clutch washers / Plate on a rear clutch motor



With the clutch basket in place:

1)Place the thicker slotted washer on the main shaft and turn 1/8 turn to expose the slots in the shaft

2)Place the thinner pronged washer points down or tward the engine

3)Place the Hub with threaded towers down / centered

4)Stack plates starting with fiber first , aligning inner tabs

5)Place hub down , washer , tighten lock nut



Mechanical Theory:

The Basket can spin freely on the main shaft

and the hub is locked to the main shaft

the two only connect via the friction of the clutch plates
 
#46 ·
Thanks to Panic Grip i can add more info directly to our online Tech Data Base again

Way to go man !!



Just added:

Understanding Cam Gear Ratios - TBolt USA Tech Database!



4 Stroke engine crankshaft/camshaft gear ratio is always 2:1, which means that for every two revolutions of the crankshaft the camshaft will rotate through one revolution.

This is a 2:1 ratio and must always remain

The top cam sprocket will have twice as many teeth as the crankshaft cam-chain sprocket.

Typically, Honda 50 and 50-110cc Chinese engines and Lifan 140, have 28 tooth cam sprockets.

Jailing and GPX and YX 140 engines have a 32 Tooth cam sprocket.

When installing a performance camshaft you may replace the cam sprocket but only due to the bolt pattern.

The new cam sprocket must have the same tooth count as the original sprocket.
 
#48 ·
BIG KLX TYPE Pit bike motor port TECH DATA

YX150/160

A type head - Honda intake & Honda EXH ports

B type head - KLX intake & KLX EXH ports



ZS155cc

B type head - KLX intake & EXH ports

C type head - KLX intake & Honda EXH ports
 
#51 ·
We have been adding to the tech data over the years as we have more info to share
here is a cool one from a great PM member

LINK:
Microphone Pipe
 
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