After the melt down I had a few weeks ago from running lean after changing my air filter setup, I'm now back up and running along with a few more mods or lets just say I pulled out my Dremel and started grinding someone. First of all I don't want to seem like I'm bragging but I'm happy as can be with these new modifications and this is just some free info I want to share for anyone that's like me and likes to tinker with there own toys to make them fast instead of paying big$$$ to the pro-builders just to get similar results so here it is:
#1) I port matched my cases to the joining jugs feeding transfer tunnels, this alone was allot of grinding since they where way smaller than the receiving tunnels.
#2) Then I raised my cylinder transfer port windows 1mm
#3) took the jugs to the machinist to over bore to .020
#4) Installed a set of Vito's +.020 power pistons which I was very tempted to cut there windows bigger but instead left them alone to see what there higher windows would do alone.These pistons are very nice and come with a one piece base gasket that is already matched to the jugs transfer tunnels so this was what I used as a cutout template for the case.
#5) Went up 3 main jet sizes and still running a bit lean, so today I will go up 2 more and I should be close.

I'm running 16/41 sprockets that before the rebuild I wasn't able to break the rear end loose in 6th gear on loose terrain no matter how hard I got on the throttle, but now 1/2 throttle and it sliding silly everywhere, and on asphalt I can be rolling in 3rd gear and nail the throttle and when the powerband hits it puts the nose in the sky!

 

Doesnt success feel good?

-Nick

 

Yea, and fast as hell...........

 

Congrats, i bet that thing is hard to hold when the powerband kicks in!

 

good job and have fun riding it.

 

Case matching is said to add 2HP.

DId you raise the exhaust port or just the transfers? Did you widen the transfers? How did you get into the transfers? DId you change the roof angle? Did you do anything to the intakes?

 

The exhuast port was widen alot and only raised alittle when I first did my porting along with major opening of the intake ports and boost port but never got to my transfers. Now this time around I got to the transfers with a 90 degree dremel attachment with a small angled bits and I did not change any of the roof angles at all just or widened them only raised them about 1mm so it was a smooth flow out which before the sleeve was very mismatched with the port window that block / threw off the flow angle.

It was a pain to work with that 90 degree tool since it barly fits so I had to change alot of bits frenquently according to the angle I needed since the tool doesn't allow for you to change it by simply moving the tool because it barly fits. This is what you should use instead a FOREDOM hand piece # 56A along with a Foredom flexshaft motor. I'm thinking of buying one and doing alittle porting on the side for a coupe of my friends that are begging me to work on there Banshee's but between work, school, son, yard work and then fitting in ridding time I have been putting them off even though it is alot of fun and the thrill of the finished product is payment enough, also this keeps them behind my roost...heheh
But I'm seriously thinking about doing it with the right tools it would be alot easier and this could make me some spare coin for future needed suspension mods.

 

good work. mine will lift up in third about a foot and a half but it wont reach for the sky.

 

A friend and I are looking into a setup like that for porting. However the $800 price tag is keeping us back. That foot pedal would be great.

Raising your exhaust 2mm from stock (stock is 30mm from the deck down so raise it to 28mm) is a huge power increase on the banshee. Since you already have the transfers opened, case matched, etc. This should be good for mid 60HP. My setup is FTZ porting with 2mm raise, stock cut head, 35.5 mikunis, ported stock reed cages, CPI inframes and it dynoed at 63 before changes (head, V-force, carbs) and tuning. Now I would say it is about 65 HP.

 

Are you talking about the tools? I would check ebay for the flex-shaft motor and just buy the handpiece new, this would be roughly cost about $350-$450