Complete Documentation of a Big Bore Project!

Today we are releasing a new series of articles on the Clinic that document a complete engine tear down and reassembly. Randy Fox (associate Publisher here at the Clinic) decided to go big bore on his Road Star and documented the process from start to finish. This is an incredible addition to our Tech Tips library, with a total of nineteen articles from start to finish.

In order to make it easy to follow, and to keep the structure easy to navigate, we have created a new category under our "Engine" section in our Tech Tips called "Engine Tear Down and Reassembly Series". As is usually the case with Randy's Tech Tip articles, each is well thought out, easy to read, and easy to understand. Randy has taken the time to create an index for the whole series that briefly explains what each article is about, and the order they should read. This series is a must read for any Road Star rider who likes to maintain their own bike.

About this series:

Introduction

The stock coils are prone to leaking so much spark that some riders have observed large arcing from their coils to the frame or tank on a dark night. Yikes! As a result, many owners have wrapped their coils with electrician's tape--an adequate, if un-elegant, solution.

Idiot Disclaimer: Do not run your engine in an enclosed space to achieve darkness. Do not touch coils or sparkplug wires while the engine is running.

I wrapped my coils with electrical tape several years ago, and it did seem to help smooth the idle a bit. But then I read that many owners were tracing various engine difficulties--especially plug fouling and carbon build-up--to sparkplug wire issues. It was discovered that the stock wires have excessively high electrical resistance. In fact, owners that modified their stock plug wires reported easier starting, smoother idle, and less carbon build-up. The stock sparkplug wires are built right into the coils, so you can't replace the the wires without also replacing the coils. When Nemesis Racing announced their introduction of high performance coils and plug wires, I decided it was time to replace mine. There are two, primary, options for aftermarket coils for the Road Star:

• Dynatech, (Dyna Performance Electronics, Glendora, CA)
• Nemesis Racing, (Nemesis Racing, g_wicks@bigpond.net.au, Australia, or powdercoatka@aol.com in North America.)

I opted for the Nemesis ones, as I have had excellent results with their other products, and, though I am not an electrical guru, I knew that matching component specs was important. Here's what Joel (Odo) Parker (Road Star Clinic author, and professional Yamaha mechanic) has to say:

"Our coils are rated at 1.53 ~ 2.07 ohm resistance, (99 to 03's), so, getting that rating right in there with how our systems work, is essential. The Dyna coils for our R*'s are 2.2 ohms, (A little too high). The Nemesis coils are 1.5 ohms, ('JUUUSSSTTT' right. :-)). More spark for the system.”

Introduction

The stock Road Star starter has a tough life even in the best of circumstances. You've probably thought so yourself at times--maybe when the weather turns cold and your battery is not as young as it use to be, or maybe every time you hit the starter button with your big-bore engine.

The starter is adequate for a stock engine with a new battery on a warm day. But if you repeatedly start your bike under more challenging circumstances, you might be asking for starter trouble.

This article covers two solutions which can be done separately, but should be done in order:

1. Replace your stock starter wires with 4 gauge cable. This dramatically reduces the resistance caused by inadequately small wiring. The undersized, stock starter wires, and the associated resistance, can lead to premature starter failure.
2. Swap out your stock starter for a Road Star Warrior starter. The Warrior starter has about 30% greater cranking power--even over the 1700 (102ci) models. Note: This option may not be necessary (but still desirable) if your pistons are stock, and you maintain your battery's charge.

• Bulldogs Custom Starter Cable kit, available from www.bulldogscustomcycle.com. Tip: Some riders have created their own cables by purchasing bulk cable from an auto parts store, and having terminal-ends fastened on. I opted for the Bulldogs kit because it is sealed against corrosion. I also felt that the time it would take to remove the stock cable, then measure, buy, and fastener-ize a homemade cable wasn't worth saving a few bucks.
• Warrior starter, complete with oil seal O-ring. Note: I opted for a nice, chrome starter from www.sxygramps.com.
• Wire ties, medium length (6-inch or so). Qty: 1 or 2, (optional).
• Dielectric (silicone) grease, to protect the terminal ends of the cable from corrosion.

The stock Road Star ignition module does an adequate job of controlling the sparkplug timing and RPM limitations, as long as you're running a reasonably stock engine, stock carburetor--and you don't mind being limited to 4,250 rpm for 1600 series engines, or 4,750 rpm for 1700 series engines. But if you want to install an aftermarket carb, increase the rev limit, add high compression pistons, or go big-bore, you'll need to replace that little black box with a Dyna 3000 or SpeedStar, direct replacement, ignition module.

Parts List:

• Dyna 3000 or SpeedStar ignition module

If you intend to cut an access hole in the battery box for the Dyna 3000 dip-switches, the following optional parts are for making a protective insert for the dip-switches:

• Small foam brush
• Plastic shopping bag

This bike is known for not using oil and responds well to different flavors of dino or synthetic oils. Your bike will let you know what it likes as you try some different options in oil selection. Lately I've been using Royal Purple 20W50 Synthetic, which in my opinion has given good results of lower engine noise and possibly a cooler running engine.

I like to change my oil at 5000-mile intervals with the synthetic oil and have found the procedure of changing it quite simple. A one beer job, unless you are like me and tend to sit back and admire the beauty of the bike. So lets take a look at this simple procedure.

Tools Required:

1. Funnel
2. Rubber mallet
3. Shallow drain pan
4. Small oil filter wrench
5. 3/8" 17mm socket, small extension, and rachet
6. Two each 2x4 boards screwed together
7. 3/8" torque wrench
8. 17mm craftsman box-end wrench cut short

Have you ever wished that Yamaha had made the Road Star with an optional Fairing like the one available on a Harley Davidson dresser? Well you can add one yourself and it is not that hard to do. There is probably a dozen different ways to go about mounting this fairing on the bike. This is just the way that I did it. I’m sure there are things that I have forgotten or overlooked, so I’ll apologize up front for that. This is not a mod that you should be in a hurry with. You will be doing a lot of trimming on the inner fairing and it’s better to go slowly and trim a little at a time than to cut too much and not be able to fix it. I probably spent at least 20 hours or so getting everything done over a few days. It was actually a lot of fun, but I was nervous about how it would turn out. If you take your time, you will be proud of it after you finish.

NEEDLE VALVE SET REPLACEMENT

Reason for changing the STOCK needle float valve set

I own a 2000 Silverado, and love this bike.  Shortly after I had the bike broken in, I decided to see what our rides could do flat out.  Well at just under 100MPH, the bike stuttered a bit and began missing.  I attributed that to the “REV LIMITER” kicking in.  To make a long story short, this spring, still with the same bike, but now with Samson Shogun 2 ¼ inch full pipe system and Küryakyn twin velocity breather, perfectly jetted, I seemed to be hitting that so called REV LIMITER earlier.  This caused me to investigate this problem further.

After sacrificing ride time and some cash, using my own ride as test vehicle … You can read the post to follow the history;
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