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June 5th, 2014, 05:58 PM   #1
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Aftermarket or custom Conrods Pistons pins

seems to be a common question particularly for older bikes.

for the old bikes you can check the parts listings in service manuals on the left of the main page and then search for them at the munn racing fiche.

I've found some "no longer available parts" for my 02 by checking individually with husaberg dealers and parts suppliers all over the world.

for example Rick bozarth at boss offroad and Dan at moto exotica are great people to ask for this kind of stuff.

if I can't get piston or a rod for an older bike, even kwakas and suzis need rods I look first to the catalogs of prox and carillo for the rods and wossner for the piston specs.

http://www.pro-x.com/downloads/technical.pdf

http://wossneronline.com/2014_wosson...ns_catalog.pdf

carillo rods on page 64 Catalogs

what I do is measure the squish, piston to valve clearance and the Compression ratio, measure up the rod the big end pin and the piston including piston volume.

for a good example of checking the piston to valve clearance see Dr_Cs videos I won't tell you which one its in you have to watch them all

example of rod dimensions required thanks Wardog



the pins obviously you need OD and length but also oil gallery placement and weight should also be considered.

for balancing and crank welding info check here Balancing an 80mm 650 crank

with the right information I am able to choose rod/pistons that work even if they are not listed for that model.

when the gallery is back up there will be most berg rods in 3d models and ISO drawings. Conrod Drawings

the hardest bit is usually the pin, Trick titanium will make you anything you want in steel or Ti .. for a price. Alpha bearings in the UK is another contact, there are heaps of people with pin grinders but most are old school and don't do the inter web, ask around locally.

If you need to modify a pin to make it work eg a proX pin kawasaki honda suzi yam or a Jawa pin you can have the ends ground cylindrically to the correct Diameter and also if needed have this done on an offset to adjust the required rod length or machine out the crankpin bore in the crank to achieve the same thing.

Husaberg/KTM hybrid engine





this a good one, big end pin made from a rover piston pin 1994 501 conrod?

if the big end oil holes do not align take a 3mm diamond coated spherical burr in a die grinder and grind a 1-2mm deep groove in the ID of the crank pin bore to connect the oil passages. if the oil passages require enlarging use diamond coated burrs, if the pin is too long grind it down, if the pin is too short split the difference either side and weld the pin ends.

its sometimes a little disheartening when parts are discontinued but Rods pins and Pistons are the bread and butter of single cylinder internal combustion engines and with the inter web resources we have, they are relatively easy to obtain.

.
Thanks from Dr_C, makazica, Goose916 and 2 others
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June 5th, 2014, 10:36 PM   #2
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I couldn't find the thanks button on this tablet thingy.

Thanks!
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June 6th, 2014, 01:43 AM   #3
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I would love to make a rod
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June 6th, 2014, 04:55 PM   #4
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me too

I have an idea to use carbon tow inside a cromoly tube

CF rods were tried in F1 before the ban .. interestingly the main issue in those engines was fatigue cracking of the crankshaft

aluminium rod shouldn't be too hard to make .. we just need more room inside the cases

BME Forged Aluminum Rods



the MMX rods look fantastic as well but the price is pretty funny
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June 8th, 2014, 09:01 AM   #5
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Good post bushie! you are a veritable treasure trove of information cheers mate.
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June 9th, 2014, 11:26 AM   #6
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For those who doesn't already know.

MX Composites


FWIW
SuperMoto boys here in Sweden tried them a couple of years ago with some rumors of trouble with the bearing surface between conrod and big end pin, haven't heard anything of that from the Enduro riders.


Regards

/Nick

Last edited by Ghost; June 9th, 2014 at 11:45 AM.
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June 9th, 2014, 04:28 PM   #7
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no worries lads

JBS racing also tried the MMX ... plain big end failure was a problem





perhaps less HP and a higher oil pressure may have worked

IHMO plain big ends are long overdue in dirtbikes

the new huskykatobergs have had pankl rods with plain big ends for a few years now.



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June 9th, 2014, 05:38 PM   #8
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Desiring to understand - What are the advantages / disadvantages of plain bearings? Are they in theory retrofittable?
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June 9th, 2014, 10:57 PM   #9
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mostly there is no big end cage to cause premature wear of the rod

something perhaps less obvious is that if they do fail the bore/ piston/rings and mains etc are usually still OK because there isn't as much hard metal debris

main disadvantage is they need more oil pressure that cannot be interrupted

they should be retrofitable but you'd have to closely examine a new 501 to see exactly how they did it. pin diam, clearance, oil pressure, flow rates. BMEP etc
Thanks from tourist and FE350
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June 10th, 2014, 04:37 PM   #10
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out of my league atm but something to chew on! interesting, thanks!
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