Flash 5 Rises Like a Phoenix from the Ashes of F3

[Wheelman-111]

Greetings:

Work progressed a little further last night. Heeding King's advice, seeing no reason why not to eliminate the Lip on the Left transfer port, I got to work:

F5LTransferPorted[1].jpg (147.7 KiB) Viewed 3320 times

There used to be a ledge on the right side of the pic at the case port corner.

F5LTransfrPorted[1].jpg (164.13 KiB) Viewed 3319 times

Now using Highly Sophisticated Wheelman Rock-and-Stick Toolkit, prepared to munch out a proper Malossi-sized Boost Port:

F5TrPortCutting.jpg (174.11 KiB) Viewed 3319 times

It actually came out pretty well.

Now it's very important that all parts be cleansed of Al-You-Minnie-Yum shavings prior to assembly. I use the Honda-san-Approved Parts Cleaner 99215-HOB-ARTS:

F5DishwasherCases.jpg (143.11 KiB) Viewed 3319 times

Don' nobody tell Ms. Wheelperson, OK?

[LMH]

Thats a perty case there in the dish drainer

[bakaracer]

Hmmmm. Wonder where king learned that from?

[kingkamehameha]

Hmmmm. Wonder where king learned that from?

All credit goes to bakaracer!!!!!!! Everything i learned about porting he taught me. Thanks brian you da man long time no talk! Im coming to the mainland for the first time in february we should kick it and have a few beers.

[paulpauly7]

its not new news about that lip any good builder should know about it

[Wheelman-111]

Greetings:

Quoth PaulPauly:

not new news about that lip any good builder should know about it

That would explain why I didn't know anything about it...
Dishwasher-Safe Crankcases prepped and ready. It's Christmas in Deepinnaharta, thanks to Red Eft Performance:

F5MalossiBoxesCat.jpg (126.01 KiB) Viewed 3258 times

Ms. MiMew likes Malossi.
Time for a shout out to Red Eft. Here's a true-blue American selling fine Eye-Talian Exotica for an affordable price. I had really good luck with Malossi in Flash 2 - a 65cc SE/05 Iron kit. Unlike the eBay sellers, Red sells for something less than the value of my pancreas on the Organ Donor Black Market.

It's good to have a fellow Forumista who knows a thing or two about building scooters as a vendor. The only other source for Malossi was some guy with a weird name from overseas, like New York. Product arrived almost as soon as I hung up the phone/pressed "Pay Now". Compared Honda-san and Malossi cranks:

F5CrankStockMalossi.jpg (174.88 KiB) Viewed 3258 times

Despite all the "Stuffer" extra material, Malossi's NiCRMo crank is only a couple ounces heavier than Honda's. Propaganda says the "...crankshaft is the heart of an endothermic engine." and features "Dynamic Balancing for speeds up to 16,000 RPM." I doubt the Iron cylinder will ever see that dizzying number, but good to know there's something in reserve.

So I froze my new Honda bearings, and baked the cases at 325F. for 25 minutes, or until all the cheese is melted and the crust is a light golden b... Uh, never mind.

F5BearingHotInstall.jpg (141.56 KiB) Viewed 3257 times

Seriously, the lubed and frozen bearings dropped into the cases with nothing more than a light tap. It's a beautiful thing. (*Sniff*).

[kingkamehameha]

Greetings:

Quoth PaulPauly:

not new news about that lip any good builder should know about it

That would explain why I didn't know anything about it...
Dishwasher-Safe Crankcases prepped and ready. It's Christmas in Deepinnaharta, thanks to Red Eft Performance:

F5MalossiBoxesCat.jpg

Ms. MiMew likes Malossi.
Time for a shout out to Red Eft. Here's a true-blue American selling fine Eye-Talian Exotica for an affordable price. I had really good luck with Malossi in Flash 2 - a 65cc SE/05 Iron kit. Unlike the eBay sellers, Red sells for something less than the value of my pancreas on the Organ Donor Black Market.

It's good to have a fellow Forumista who knows a thing or two about building scooters as a vendor. The only other source for Malossi was some guy with a weird name from overseas, like New York. Product arrived almost as soon as I hung up the phone/pressed "Pay Now". Compared Honda-san and Malossi cranks:

F5CrankStockMalossi.jpg

Despite all the "Stuffer" extra material, Malossi's NiCRMo crank is only a couple ounces heavier than Honda's. Propaganda says the "...crankshaft is the heart of an endothermic engine." and features "Dynamic Balancing for speeds up to 16,000 RPM." I doubt the Iron cylinder will ever see that dizzying number, but good to know there's something in reserve.

So I froze my new Honda bearings, and baked the cases at 325F. for 25 minutes, or until all the cheese is melted and the crust is a light golden b... Uh, never mind.

F5BearingHotInstall.jpg

Seriously, the lubed and frozen bearings dropped into the cases with nothing more than a light tap. It's a beautiful thing. (*Sniff*).

Have you changed the bearings before? I have had the hardest time with virgin elite blocks. I have to use a heat gun and roast it pretty good. The sym cases all allow bearings to drop right in because the porous material heats faster. I also noticed that blocks that have had bearings changed before are alot easier to do than "virgins" haha

[Wheelman-111]

Greetings:

I've swapped main bearings at least 5-6 times now all told. Frankly no, I really never have had trouble tapping them in. Heat and Freeze seems to work like Buttah, every time. The real trick is dropping the bearing in perfectly straight, while ignoring the third-degree burns from the searing-hot cases.

A heat gun might work, but getting the whole case up to 300+F. gives a lot of working time. The frozen bearings get a little frosty coating on them, and they literally sizzle as they almost fall into position. Maybe a first-time case is a bit tighter, but not so you notice. Anyway, like virgins, a tight grip on the bearing is a Very Good Thing. Otherwise the outer race is at risk to develop a microscopic wobble. If that happens, the life of the bearing is measured in seconds.

[Wheelman-111]

Greetings:

Finally getting around to assembly:

F5MalossiMockup.jpg (166.4 KiB) Viewed 3246 times

Fresh tube of HondaBond, little cup of Motul, big tube of H-D grease for the paper gaskets all ready to go. Funny thing; The brown HD Special Purpose grease immediately turns to Blood whenever it touches a Honda aluminum part.

[Downsouthdio]

... I dont even watch tv.. I just come on here..hahaha

[bakaracer]

Is that a malossi cast iron bore? If so, your not going to be near the performance of the corsa you had. The mhr aluminum is in the same performance class as the corsa

[Wheelman-111]

Greetings:

Yes, Baka-san. And may I say, Good Eye.
I think I am prepared to accept a league less performance to regain Civility and perhaps reliability.
No complaints with the Corsa, but the trouble with a racing engine is that it's only happy when it's racing. Too much smoke, drama and noise for a trip to the Dry Cleaners. If I can squeeze out 55 but can drop RPM to cruise quietly at 35, that's more like the performance I need. I am not prepared to say I won't try an MHR sometime down the road, but I hope I can be happy with less.

[kingkamehameha]

Baka is right the cast iron is a VERY different bore but you wont be dissapointed compared to a nicklesil or ruima. It also does nice with queit pipes that dont rev as high. You will be happy with the porting and crank for sure. You still need a extra head gasket tho

[Wheelman-111]

Greetings:

I had a look at the meat in the exhaust port of the Iron Malossi. Yikes it's like 23mm. My ADV pipe is 29. Is this going to present a problem? If so what modifications might be recommended?

For sure I'll smooth out the casting ridges top and bottom and polish up the whole thing, but I'm not sure I'll live long enough to hog out the port to the full diameter of the gasket flange. Is this even worth doing?

If the big pipe is going to pose a problem, I'll opt for a smaller one.
Hello, Red Eft?

[curtis966]

I'm very interested in all this porting. Can it be done to my af05 as well?
86 aero
Ruckus vari 6.3 rollers
Malossi wild lion pipe
Stock carb with a #90 jet