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Discussion Starter #1
My TW is finally reassembled and back on the trail after munching it's top end in Moab. Thanks to the enormous generosity of TW-Brian and elime my '03 Betty Boop got a make-over with a reconditioned head and a larger high compression Wiseco piston fit in a 1 mm over-sized old-style cylinder. Tony seems to do good work 'cause Betty sure wanted to romp with greater authority on a quick test ride yesterday. The noted performance improvement may be due to a good valve grind and better, higher compression. Maybe forged piston is lighter? Or crisper air/fuel metering? Anyways bike seems to want to rev up quicker and put out more power in mid to upper range. I may have to adapt my riding style to accommodate as historically I typically played in the torquey bottom end. We shall see. Snowed last night up high, and is still rainy here at 5,200 ft. Will change oil and if rain stops I shall take Brian's loaned valve compression tool to the post office then go get muddy. Vroom!
Thanks to all for their support and best wishes. Special thanks to Mel and Borneo for loaning me their TWs to get a few more days of riding in while at the Moab group ride. I felt honored by their trust since I had a proven record of recently blowing up Betty twice. And of course tremendous gratitude for the used parts and guidance from Brian and Tony. Tony was so apprehensive that I be pleased with his piston/cylinder pair that he didn't want me to pay until satisfied. What a guy! Great Forum, even better members...thanks.
 

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YEAH !!!!!!! Betty is alive and well. Awesome to hear Fred. Hope the weather will cooperate and you can give her a good break in.- Glenn

P.S.- YEAH !!!!!!!!!!!!!!!
 
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Well done to all concerned (and I mean that) – good to see that Fred has the support he needed, (braces aside) when he and Betty needed it the most.

Fred – may you have many (oil filled) and happy memories on her – (and this time, if she fails you, you’ll know who to blame) ……..
 

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Fred,

So glad you got Betty Boop up and running. beer.gif Huge kudo's to TW-Brian and elime, almost makes me tear up reading about the success! Almost! fpalm.gif

I feel bad the head I sent you was defect and hope I didn't wreck it somehow before sending it your way. It sure didn't last long. Did both your original head and my replacement have the same fault/problem? If so, any idea what it could have been on them?

Anyway, so glad you're back up. It was so great Borneo and Mel loaned their TW's to you, but I know you probably had a weird feeling of what had happened to yours. If anything, your gaining a ton of engine repair/replace experience.

Time to zip up the jacket, throw a leg over the saddle, and head on down the trail.

Take Care
 

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Discussion Starter #8
Not fault of admiral's head. Loose adjuster nut on intake caused problem, not stripped exhaust cover bolt and low oil level I think. I didn't tighten things up enough after playing with Gerry's gift of a valve adjusting tool.
 
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Fred,
I knew with rusty nuts the size of yours, Betty Boop was destined to run. Glad to hear you are on the road again. I road that white TW of mine the other day, and couldn't tell you had even been on it!
Mel
 

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Fred -- Glad to hear it is all working out well. When you change the oil use regular dino oil (NON synthetic) for the first 1500 miles to make sure the rings seat.

I still haven't cashed your check (Fred paid me even though I told him to wait until he saw how the new piston / honed out cylinder worked) but with this latest report I am getting very close to taking it to the bank.

Wow! More power, speed, and hopefully economy. This just may be a reasonable problem free upgrade for TW's that need a base gasket change. Just a thought. Tony
 

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Discussion Starter #12
Thanks Tony, fresh non-synthetic oil installed yesterday before my ride. Go ahead and cash that check, I'm a happy camper.
I removed my hard wired USB port since it's constant 20 milliamp draw seems to discharge battery. I installed USB plus a new AGM battery on eve of Moab trip and now battery will not hold a charge. Factory defective perhaps? Low voltage on then new AGM had me using my kick starter frequently during the Moab group Ride. Betty Boop is now running on older five year old wet cell battery.
 

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Glad to here your back on the road. Be careful with all that new power, remember the Avatar :p
 
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Discussion Starter #15
I need to put some more miles on to truly evaluate the piston, and unless it blows up what I can report will be somewhat subjective since I made several changes at once.
First off the head came off of a salvage bike with an unknown history other than being heavily carbon fouled. While cleaning that up I got carried away with my dremel tool and ground/polished/ improved a lot of casting irregularities in the intake and exhaust ports.
I did a good valve grind too and plan to measure compression after rings seat a bit more. My old engine before failure showed only a paltry ~95 psi or so.
I also leaned out my mixture screw from 2.5 to 2 revolutions out since old plug came out looking rich. Other jetting is CA stock for a 2003, no needle shims or other trickery.
And lastly the higher compression has me cautiously starting out with 91 octane while previously I burned regular. No alcohol-free fuel seems readily available here.
My initial impression is of a motorcycle that wants to accelerate a bit more briskly with a somewhat stronger mid-range to upper range based on the seat-of-the-pants dynometer. I don't think I will need to re-jet but I may want to fiddle a bit to gain, or re-gain more bottom end grunt.
 

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Discussion Starter #16
Thanks Top, I'll have to watch out for wild wheelies now. However I think both I and Betty Boop are both a good 40 pounds+ heavier than my 30 year old avatar picture and bike, so thus are better restrained by force of gravity.
 
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I'm satisfied. Consider your check cashed as of Monday sometime. I will use the money to buy more Wiseco pistons -- if I can find some reasonably priced ones.

Sorry to hear about your AGM battery. I went out to my TW's not having run them in the last 3 months and they started right up. Maybe I got the only two good batteries they made.
 

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Discussion Starter #18
I bought two, one for my brother's and one for mine at the same time to save shipping costs. I hope his performs better than mine which refuses to hold more than ~9.6 volts and is only 6 weeks old. Some Moabidians might recall my bike's reluctance to start solely on the e-button and my often assist with a quick stab at the kickstarter...in hindsight that sure seems a sign of a failing battery.

Edit: Open Letter To Yamaha: Please Bring Back The Original Equipment Kick Starter!
 
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I just replaced the battery in my bike that I had in Moab. I think the 110 mile run shook them up so bad the plates just shorted out. The one I replace was not that old, less than a year for sure.
 

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Discussion Starter #20
Randall, was your bad battery a classic wet cell, or AMG?
 
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