"PureStock" Zeda80 build.

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This will be a long build as 60 plus hours a week of work fill in the majority of my time...I'll be adding some reserve posts for the purpose of keeping the build all together.

My goal for this build is to coax all I can from this motor in stock form by either enhancing its good points and or correcting original design flaws before trying the latest performance bolt ons like a better carburetor,air filter, intake manifold and exhaust from the aftermarket.

No major porting or timing changes will be performed and all the factory parts and pieces will be used aside from improving on the reliability of the bottom end with some upgrades.

So, on to the game plan below.

(Bottom end)
*Stock factory balanced crankshaft.
* Seal retainer plate.
* Factory connecting rod lightened and oil holes chamfered to improve oiling.
* VXB 10x14x15 upper rod bearing.
* Factory piston pin drilled to lighten.
* Factory piston lightened from the underside..All sharp edges smoothed to help eliminate stress cracks that cause failure..oiling holes chamfered.
* RB Tech 6202 RS2 C3 Crankshaft bearings.
* RB Tech 6202 RS2 C3 clutch bearings.
* OZ Super Magneto (only because the spark should be better to begin with.)

(Top end)
* Cylinder:
1. All port entries including transfers will receive a light radius to eliminate all sharp edges and aid in improved flow.

2. Intake port will be given a semi rough finish to aid in fuel atomisation.

3. Exhaust port will be smoothed and highly polished.

4. Transfer port sides nearest the exhaust port side will be filled with epoxy or jb weld and re shaped to direct the flow of mixture to the intake side of the combustion chamber where it belongs.

A decent percentage of your air/fuel mixture is wasted out of the exhaust port due to this transfer port design flaw.

(Cylinder Head)
* Light sanding of the mating surface to ensure proper sealing.
* Re-chambered with a 47mm wide squish band to match the piston . (Stock squish 44mm)

The rest of it such as the 14mm carburetor and air filter along with the intake manifold, and exhaust pipe will be used in this build and modified or enhanced in any way possible to get the most out of them.

Expect to see some bolt on upgrades at some point as I feel I've reached full potential using the stock components.

Here's the motor as shipped which is the 2017 model...The motor did come with the rest of the parts to complete a full install but most of that will not be used once I'm ready to install the motor on a bike

 

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Some pics of progress on the cylinder clean up.

Stock exhaust port.

After removing casting flash and a sanding roll clean up.

I'll go over the port with an abrasive pad wheel then do a semi mirror like polishing to finish to the port...calling this good enough.

Stock intake port..Casting flash was really bad in every port.

Cleaned up and finished,leaving the rough surface created by the 180 grit sanding roll to aid in atomization of the fuel.

I'll be making my own intake and exhaust gaskets as the stock SQUARE gasket for a ROUND exhaust port is a big joke and the intake gasket to match the stock semi oval shape of the intake port.

I'm not exactly sure why but one side of the exhaust entry port seems to have been cast higher on one side...All i did was clean off the rough flash and you can see the shape remains the same as stock just more pronounced.

Transfer port clean up coming next.

 

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I cleaned up the bottom skirt edge of the transfer port..very little material was needed to be taken off to accomplish a nice rounded curve...I did first file the bottom edge flat as the rough casting was horrible leaving pits and an uneven surface.

The radius was done by hand using a small file and you can see on the bottom pic the material left to maintain skirt strength.. no super sharp knife edging necessary.

Im far from finished with the transfer ports in general..more to be added.

Cleaned up the sharp edge casting that blocks flow out of the intake sides of the transfers...shouldn't be much of a disturbance left with flow to the intake side now...Some better tools in the future will help get better results next time but im happy for now.

Now to deal with the exhaust side.

 

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Started on the piston work.

What i did was smooth any and all sharp edges on the piston...The reason behind this is to eliminate stress fractures that typically occur within sharp edges.


Just simply take the edges down with a fine file and go over it with some 1000 grit to ensure the edges are smooth and not sharp.....it's not really all that much work for some added insurance.

Skirt area inside and out.

Piston pin area

Improved oiling.

Figured I would see what has been removed thus far and I managed 1 gram of weight removal by cleaning up sharp edges and what material I removed improving the oiling.

Stock piston/rings.

With work above

Stock pin weight

Stock upper bearing 10x14x13

Gillardoni "competition race" bearing
10x14x13

VXB 10x14x15 oversize bearing

Much to my surprise the gillardoni bearing was slightly heavier than the stock bearing..I figured it the other way around..And of course the VXB bearing adds quite a bit of weight...With adding shims to both sides i'm thinking about a full gram or more ADDED to the upper end using the VXB over a stock bearing.

 

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Modding of the stock carburetor , intake manifold and, exhaust.

( Stock NT 14mm carburetor)
1. Gutted entry area.
2. Built in velocity chamber.
3. Cut center out of plastic seal.
4. Air filter cover mods ( coming soon)
Just a quick before and after shot.

(Stock aluminum intake manifold)
1. Port matched.
2. Cleaned up any and all edges ..smoothed throughout entire port.
3. Inlet bored out with a sanding drum to 15mm..I think I can get 16mm maybe 17mm out of it.

Stock exhaust
1. Ground out the flange and added a smooth edge free entry into the 19.7mm i.d. of the stock tube.

Stock exhaust port diameter measured 20.7mm....If you count the outer radius of the exhaust flange blending , the diameter is closer to a 20mm plus diameter that will mate up to the exhaust port....close enough for me for now..More to come with the internal muffler mods as i do them.

I will be making my own exhaust gasket so once I have it I'll more closely match the exhaust flange with the stock port for a perfect match up.

To be continued...

 

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Started cleaning up on the cylinder and my rotory tool took a crap...I'll be getting a new one and finishing it...Left some pics of the exhaust port work in one of the reserve spots above.