Looper exhaust porting

[powerabout]

You only need a rod and then work out how to squeeze the sides together using a 3 angles on each side of the rod. The consumer tool screws up and the factory one is spring loaded as I remember it.

[Captain75]

I have no alignment tool.
Just tryin to do it according to the book.
On most of the rods/caps I can get it flush on one side, but with a slight, feelable missalignment on the other, how is that possible?
I guess I will have to manage with the best I can do since its time to get boat in the water.

[powerabout]

Put a small amount of pressure on the bolts, get a pencil to check the 6 alignment faces, get a tiny hammer to gently tap the cap to align it.

[Captain75]

Thanks for the tips!
The procedure pretty much describes my work so far.
I have no problem sideways(the small alignment areas) my problem occurs along the two bigger areas. I seem to get it slick on one side, but still some off alignment on the other...
I have thought about using a clamp during the torque process.

My intention is to get the engine running after this weekend, right now I traveling to London with my 10year old son(He's about to see one of the worlds great cities for the first time)and I am trying to gather info on the process. In worst case I will have to use another rod, something I don't want to do due to my balancing effort during the rebuild.

I don't think it is possible to find an alignment tool in this country.

[Captain75]

I managed to get them right, I think.
Since I am really close to start, I have some more questions(I might have asked similar things before..)
- Do I have anything to benefit by removing the airbox baffle due to the mods I have done(described in this thread)
- What would be the proper jet size the use, right now I have stock 62D installed.

I just realized that I have another question;
I torqued the main bearing bolts a bit to much, not that the threads got destroyed, but a bit to much according to specs(found the specs to late..)
What do you guys think, shall I loose the bolts one at a time, add new sealer and retorque them to proper specs, or just leave them as they are?

Port map...

Powerhead in place...

[Captain75]

Only hours before first start!

pictures of crankcase stuffing and my ported intake;Fuel hose of two sizes...

No sharp bends and corners...

[warriorcookie]

What a fun thread to follow.

Good luck with the first start!

[olboatman]

What a fun thread to follow.

Good luck with the first start!

+1 Thanks for sharing!!! Gary

[Captain75]

+1 Thanks for sharing!!! Gary

Thanks guys!
Glad it made someone happy!

[baja200merk]

Make sure that you don't run ethanol those fuel hoses in the crank case counter bores will break down and end up stuck in the reeds.

Looks good

[bigbore]

I'm sure you guys already hit this topic somewhere between page 1 and 22 but I would definitely start with 6 jet sizes up and 6 down,6 down idle and mid,6 up mains.

[Captain75]

I'm sure you guys already hit this topic somewhere between page 1 and 22 but I would definitely start with 6 jet sizes up and 6 down,6 down idle and mid,6 up mains.

Thanks! I've asked the jetting question at least twice before, but with no response. Now I hve something to start with!

[wanagofass]

I didn't want to comment on jetting b/c I'm no expert but I normally start with .078 read the piston tops before running it hard then start jetting down.

[Captain75]

I didn't want to comment on jetting b/c I'm no expert but I normally start with .078 read the piston tops before running it hard then start jetting down.

.078 must be w/o airbox baffle, right?
would that be like .068 with baffle?

[wanagofass]

I've never jetted one with the baffle. Only the new style air box. '93 and newer. I think that the motors with the baffle came jetted about .010 smaller but that is a different carb also.