Piston-deck height

Deck height is defined as the distance between the top edge of the piston crown (with the piston at TDC) to the edge of the cylinder liner. The closer the edge of the piston crown is to the edge of the cylinder the high the compression ratio will be.

So if you have pistons that are 10.5:1 and they are 0.010″ below the edge of the cylinder and you are able to reduce the deck height by 0.010″ then the actual compression ratio of the cylinder will be increased.

The reduction of the piston deck height can be accomplished in several ways. Machining the cylinder block is the most common method.

A word of caution you must know exactly the minimum valve to piston clearance that is required. this varies in different engine designs. To increase the piston to valve clearance usually the valve relief pockets on the piston’s crown are enlarged or the height of the piston at TDC must be lowered in the cylinder.

Oversize Valves

Some tuners believe that larger size valves enhance Hi-RPM power at the expense of Low-RPM power. This has proven to be false due to the results of dyno tests and theory. Larger valves enhance Hi and Low RPM.

When a valve is closed it has no size whatsoever for a cylinder’s ability to induce air flow. A valve that is opened, 0.015”, appears to the cylinder as a small valve. Only when the valve reaches 25% of its total lift point does the cylinder actually experience anything near the true size of the valve. If a cylinder was stuffed with valves as big as possible to create a greater movement of the air/ fuel mixture and exhaust gasses and the larger valves proved to be excessive (too large), the solution of the problem would be to reduce the valve’s lift, besides reducing the air flow it would also reduce the wear and friction on the valve train. In the real world, the criterias for the intake and exhaust system for making peak HP and torque at a given engine RPM is the cross section area of the intake and exhaust ports, not the size of the valves.

The real advantage of using oversize valves is that, for a specific rate of the valve’s opening, an oversize valve will give a greater breathing area to the cylinder quicker. This is equal to as a smaller valve opened at higher rate of acceleration. Any time there is a higher acceleration rate in the valve train, more stress is created.

As long as valve shrouding is not a factor then the largest possible valve in a cylinder head will allow the engine to develop power over the widest RPM range, not just increase the flow at high lift rate. If a dyno test of a engine with a cylinder head that has oversize valves reveals a loss in low RPM power it is because the engines camshaft has to much overlap.

For carbureted normally aspirated Suzuki engines in the 9.5 to 12:1 compression ratio range the exhaust flow needs to be 75 percent of the intake flow. Overall when the compression ratio of an engine increases, in order to obtain the maximum results an exhaust valve can be made smaller in relation to the intake valve. This is due to the power developing earlier in the expansion cycle of a cylinder in high-compression engine, thus allowing the exhaust valve to be opened sooner and longer without any problems. A small exhaust valve will create the opportunity to use a larger intake valve.

Nitrogen

Nitrogen
RACING: NITROGEN “A GAS THAT CAN HELP YOU WIN YOUR CLASS”.

If you read my previous post about ‘AIR DENSITY’ in this thread then it will be easy to understand the advantages Nitrogen has over Air, for those who haven’t, I would recommend to do so.

The first advantage of Nitogen is for it’s use in your tires, by doing so you will eliminated tire pressure build up, this is a really important factor in order to maintain a tire’s performance criteria. The Racing Displines of Road Racing or Drag Racing require consistency of a tire performance and the use of Nitrogen will give you that advantage.

In Drag Racing when using an ‘Airshifter’, the use of Nitrogen will add the the unit’s reliability ( No Water contained in Nitrogen) and you will find that the shifter activation responce time is faster.

Longer exhaust duration

Most stock camshafts from production 4 cylinder engines manufactured today are ground with the longer exhaust lobe duration,or that they are ground with shorter intake durations. This can be viewed that either the Exhaust Ports or Exhaust Pipe system is somewhat restrictive, and needs assistance, or that the intake system is very efficient and cam timing can be trimmed back without a sacrifice in power, in order to maximize throttle response and cruising efficiency. There is no absolute correct viewpoint in a stock engine running at conservative RPM levels, for the sake of overall efficiency, fuel economy and a quiet smooth running engine, this staggering of intake and exhaust duration is quite common and appropriate.

High Performance is another thing entirely. Change one factor, such as the exhaust system installing headers and larger pipes and the need for that longer exhaust lobe has been eliminated. Now add to this change a different carb system and camshaft and you have really changed the equation. But, why is it that so many racers & cam grinders insist on running a cam with longer exhaust duration regardless of what equipment is used? The answer is habit, many have been somewhat successful in doing it this way and will never change unless forced by circumstances.

The best result comes when we realize that an engine is basically an air pump. Air is pumped in and out and there are problems when one side or the other is restricted. Balance and flow is our objective, unless you are NOT trying to make more horsepower!

Most experienced Tuners run a single pattern cam, equal on intake and exhaust duration. This type of designed cam always make more torque.

Logbooks

THE LOG BOOK:

I have 2 Log Books, the first one is for the engine and the second one is for the bike.

ENGINE LOG BOOK:
Contained in this Log is every measurement or weight of components that are subjected to wear, this includes the transmission, clutch plates, clutch springs, crankshaft, connecting rods, pistons, piston pins, piston rings, camshafts, valve guides, valve stems and valve springs, drive chain and sprockets . Although you may consider this time consuming the benefits are substantial. Once you have a baseline of your measurements then the next time you disassemble your engine you will have a very good picture of the wear rate of all the components. This process will virtually eliminate parts breaking from fatigue and you will be able to determine what aftermarket parts are more durable. For example I know using a certain type of piston ring in my 1327cc EFE race engine that for every 165 passes down the race track that both my top and second ring end gap wears 0.001″ of any inch. This was the same wear rate that I encountered with my 1230cc EFE race engine using the same type of piston rings. So I know that the oil that I am using is working and the quality of the part is consistant no matter what the power out put is and that after x ammount of passes I have to replace the rings before the power starts to drop. Utilizing this measurement process for the last 20 years I have found that the one part of the GS /EFE engine’s that wear out the fastest are the valve springs, and by the way I have never broken a valve spring in over 7,100 passes down the track.

RACE BIKE LOG BOOK:
In this log I list my tune-up ( jets, timming, drive sprocket size, tire psi,), in additon to the brand of race fuel and octane, my launch and shift RPM for the particular track that I am racing at. Also before I unload my bike, I list measurement of the temperture, humidity, wind direction including approximate speed, and air density and record the time of day. I remeasure and list all of the above items every hour that I am at the track. The info gained from these measurements is very beneficial when you are racing a dial-in type of class, because it makes the tune decission for every round easier. Also once you collect all of the above info you will have an insight on your bikes performance the next time you race at the same track if the weather and time of day is very close.

Intake & Exhaust Port Surface Finish

As long as the intake port surface finish is fine enough so that the highest protrusions are not above the air /fuel mixture boundary layer thickness, then improvements on the finish will have little effect on air / fuel mixture flow . A rougher finish is actually an advantage. Do not over polish an intake port because of its wet fuel flow capability.

A polished exhaust port will increase the exhaust gas flow and will reduce the potential for carbon to build up on the exhaust port surface.

In conclusion 97% of a performance gain from porting a cylinder head is from the shape of the ports and only 3% is from a polished finish.

Induction System Volumetric Efficiency

here are two real world effects that determine how much fuel/air charge can get into the cylinder. The first is that air is compressible, the second is the dynamics (acceleration/deceleration) of the air. The compressibility of the air becomes a factor when the air enters the intake port around the intake valve. The intake port/valve forms a constriction, like the throat of a nozzle. Because air is compressible, it can only be pushed through a constriction so fast. Regardless of how much pressure you apply, the maximum velocity possible through the throat of a nozzle is a velocity equal to the speed of sound .

The same effect happens at the intake valve. The ratio of the typical velocity to the intake sonic velocity is called the inlet Mach index. From the science of fluid mechanics the controlling velocity in a compressible flow system is usually the intake valve opening. For a given cylinder and valve design, the inlet Mach index is proportional to the piston speed, and that the fuel/air charge flows in faster when the piston moves down faster. Of course, at some point the constriction of the valve opening starts to limit this. When the inlet Mach index exceeds 0.5 (intake velocity equal to half the speed of sound), the volumetric efficiency falls rapidly with increasing speed. Therefore, enginest are typically designed so that the inlet Mach index does not exceed 0.5 at the highest rated speed.

The effect of this constriction shows up as a pressure drop through the intake valve. Why don’t we just open the intake valve further? Because when the valve is lifted a distance equal to 1/4 of its diameter, the area of a cylinder around the valve (that the fuel/air charge passes through, not the engine cylinder) is equal to the area of the valve face and intake port, ignoring the valve stem. Mathematically, the area of the cylinder is (2 r)(d/4). Since d = 2r, this evaluates to r2, which is the area of the intake port, the amount of additional flow through the intake port increases very slowly as the lift of the valve increases beyond 1/4 of the valve diameter.

Because of the dynamics of the fuel/air charge, the intake valve normally closes at some time after the piston passes bottom dead center. As the piston moves down, it draws the fuel/air charge into the cylinder. This movement builds up momentum in the intake manifold. When the piston reaches bottom dead center, the fuel/air charge is still flowing into the cylinder as a result of this residual momentum. Thus, at the speed desired for maximum torque, the intake valve closing is timed to correspond with the velocity of the fuel/air charge through the intake port dropping to zero. This closing will occur at some time after the piston has started the compression stroke, and will result in the maximum amount of fuel/air charge being drawn into the cylinder. This maximizes the volumetric efficiency, and maximizes the torque delivered to the crankshaft, ignoring friction effects. The angle of the crankshaft at the time the intake valve closes is called the intake valve closing angle.

So what effects does this later valve closing have at other speeds? At low speeds, the momentum built up in the intake manifold will be small, such that part of the fuel/air charge will be pushed back into the intake manifold as the piston starts up prior to the intake valve closing. At speeds above the speed for maximum torque, the constriction of intake valve opening will cause a pressure loss which will reduce the amount of fuel/air charge entering the cylinder. In either case, the amount of fuel/air charge in the cylinder is reduced, and thus the torque is reduced.

The design of the intake manifold also affects the amount of momentum built up in the flow of the fuel/air charge. The momentum of the fuel/air charge is the sum of the effect of standing waves built up from previous intake strokes keep in mind that any tube will have a resonant frequency and effect the transient wave caused by the current intake stroke. While the standing waves contribute to the overall effect, there are no sudden changes in the volumetric efficiency when the RPM of the engine is an even multiple of the natural frequency of the intake manifold.

Long, skinny intake manifold pipes give high volumetric efficiencies at low piston speeds because high momentum lots of velocity is built up in the pipe during the intake stroke. At high piston speeds, the small diameter of the intake pipe causes a constriction and the volumetric efficiency falls. Fat intake pipes show a maximum volumetric efficiency at intermediate piston speeds. However, at high piston speeds, the larger mass of the fuel/air charge in the fat intake pipe is slow to accelerate, and thus the volumetric efficiency falls off.

As the manifold pipes get shorter, the maximum gain in volumetric efficiency over having no intake manifold at all decreases. However, the gain you do get with shorter intake pipe happens over a greater range of piston speeds. Basically, it comes down to the intake manifold pipe should be designed according to the engine requirements. If you need high torque at slow piston speeds, use long skinny intake pipes. For high torque at intermediate piston speeds, use long fat intake pipes. For high torque over a wide range of piston speeds (i.e. a flat torque curve), use shorter intake pipes.

Extra shift detent spring

EXTRA SHIFT DETENT SPRING: “There Is Enough Tension In Drag Racing”

I just read a thread about adding an additional dentent spring in your GS / EFE Transmission. This is an acceptable modification for a stock activated shift linkage.

A lot of my hands on mechanical knowledge has been gained thru many decades of working as a R&D Engineer for various Automobile and Motoccyle Maufactuers such as G.M. Toyota, Isuzu, Suzuki, Yamaha, Kawasaki and H-nda. An advantage of working for these Companies is that I would spend a lot of time with a large variety of data acquisition instruments. Fortunately I was able to use and apply many of these instruments to my EFE Drag Bike.

Many of our OSS members are well aware of the fact that Drag Races are won or lossed by a thousand of a second. I have had the opportunity to do A -B -A testing methods using test instruments that are capable of taking measurements in miliseconds, comparing the use of a single or double detent springs with a MRE Pro-Airshifter.

The results of the tests (confirmed repeatability) is that a bike utilizing an MRE Pro-Airshifter will engauge a gear faster with a single spring as compared to using a double spring.

You can consider the above information as another “SSR Race Trick” donated to the OSS site. I still have several more when it comes to Suzuki transmissions that will remain propriety information.

“May The Shift Be With You”

Exhaust System Efficiency

Part of getting a large fuel/air charge into the cylinder (volumetric efficiency) has to do with getting the combustion products of the previous cycle out of the cylinder. At first thought, it would seem that simply making the exhaust valve bigger would help get the combustion products out. As it turns out, the exhaust valve can be as small as 50% the size of the intake valve without affecting the volumetric efficiency over the usual range of inlet Mach speed. Normally the exhaust valves are at least 60% the size of the intake valve. This effect may arise because the combustion products are “pushed” out of the exhaust port by the piston, while the fuel/air charge is “sucked” in the intake port, pushed only by the manifold pressure.

To enhance the removal of the combustion gasses, the intake valve is opened prior to the end of the exhaust stroke. Since both valves are open at this point, this is referred to as valve overlap. If the pressure in the intake manifold is greater than the pressure in the exhaust manifold, the in rushing fuel/air charge will help scavenge the remaining combustion products in the cylinder as the piston reaches top dead center by pushing them out the exhaust port. While some of the fuel/air charge may go out the exhaust port, an engine tuner tries to design the timing such that the exhaust valve closes just as the last of the combustion gasses leave the exhaust port. An additional benefit of valve overlap is that the intake valve is essentially fully open at the start of the intake stroke, thus reducing the pressure loss through the intake port during the intake stroke. The angle that the crankshaft turns between the intake valve opening and the exhaust valve closing is called the valve overlap angle.

Of course, scavenging does not occur at all speeds. At low speeds, the throttle valve reduces the pressure in the intake manifold, such that the intake manifold pressure is less than the exhaust manifold pressure. In this case, a small portion of the combustion products enter the intake manifold, to be pulled back into the cylinder on the intake stroke. Additionally, the combustion gasess in the space above the piston at top dead center are not scavenged. Even so, at low power settings this is not a problem.

CONCLUSION- In general, we have seen that the torque, and thus the horsepower produced by an engine depends on the amount of air that can be pumped through the engine. The more fuel/air charge drawn into the cylinder, the higher the volumetric efficiency. The higher the volumetric efficiency, the higher the torque. The biggest factor affecting the volumetric efficiency is the valve timing, specifically the valve overlap angle and the intake valve closing angle. Volumetric efficiency can also be improved by the intake manifold design. Since the camshaft used determines the valve timing, changing the camshaft will change the shape of the torque curve, and thus the horsepower curve.

Exhaust Reversion

Exhaust Reversion

There is a myth that an earlier opening of the intake valve even by 2 or 3 degrees causes the phenomenon known as reversion. This misconception is false from which other incorrect conclusions are made. When you focus on overlap you are on the wrong end of the cam-timing event.

Reversion or the effect of the backing up of the intake fuel air mixture is normally associated with longer duration high-performance camshafts, is actually caused by the intake valve closing later. The answer is in the basic principles of physics. just as with trigonometry and geometry the truth does not change because a person chooses to ignore it.

When the intake valve opens some 40 or more degrees before T.D.C. at the end of the exhaust stroke, very little exhaust gases remain in the cylinder. The piston is close T.D.C and no threat is posed to the incoming intake charge.

A false reversion theory when taken to an extreme would lead to a false conclusion that any overlapping of the intake and exhaust valves is totally undesirable. Engineers of the late 1800’s and early 1900’s used to think this way and they feared of overlap so much so they actually employed negative overlap of – 5 or -10 degrees to be sure none would occur.

The results were that these engines were severely limited to low speeds and marginal output. Engineers in the early 1920’s performed experiments with longer duration cams and proved that camshaft overlap fears are false, as both power, RPM and performance were actually improved. These engineers demonstrated that overlap did not cause engines to lock or backfire.

To further prove that reversion is not caused by earlier intake opening and the resulting extension of valve overlap, look what happens when you advance any camshaft, the intake and the exhaust valves open earlier, this advancement of the cam does not cause more reversion, yet throttle response and torque are improved.

If this myth were correct an engine would run poorly especially at lower RPM. By investigating what is occurring on the other end of the valve timing event will give you the explanation.

When a camshaft is advanced, not only do both valves open earlier but they also close earlier and there is the answer to reducing intake reversion. Closing the intake valve earlier and the reversion of the intake charge as the piston rises on the compression stroke will be reduced. It is not a mystery it is just the truth.