The intake side hinges on the fact that I'm using a 32mm carb. As you can see, the intake valve of the 230 fits nicely inside the carb:



Actually, since I'm using a 250 head, my valve is 33mm. So, my carb is 1mm smaller than my valve.

Anyway, the idea is to smooth the flow from the carb to the valve.... So, I needed to find a manifold that fit the carb exactly. Luckily, the Lakota had one, so I swiped it. [img]i/expressions/face-icon-small-happy.gif[/img]



I had to use a rat-tail file to move the holes over a bit, but other than that its a perfect fit! (JB weld on the bottom of it in that pic). $18 from bikebandit.... I had to order another one for the Lakota. It should fit the 230 perfectly. The 250 has wider bolt holes than the 230.... That's why I needed the rat-tail file.

Now I have 32mm of flow from the carb and across the manifold.... Just need to match the port entrance to the manifold and dump in some JB weld to do the motoman thing.

Illustrated pics:





Top view... Notice the vane behind the intake guide. Also I deshrouded the valves and polished the combustion chamber:



Manifold on the port:



Manifold on the carb:



View down the carb into the port and thru the manifold:

 

I shimmed the spark plug so its not in the way of the intake flow.

Here the spark plug is right:



Here the plug is wrong:



Also, with the plug installed right, the flame front begins and bounces off the top-center of the combustion chamber. With the plug wrong, it bounces off the cylinder wall and edge of the piston. I don't know how much of a difference this makes, but they sell spark plug shims just for this purpose. I figure intake flow restriction is the most important thing. No sense in having the tip of the plug blocking incomming air.

 

Here's the next piece of the puzzle:



When too much is just about right.... [img]i/expressions/face-icon-small-happy.gif[/img]



Yeah, its BIG!

 

It fits! Anymore air and I'd need forced induction (which I am looking into btw).

 

Im deff studying these pictures, and im gonna take my time with the porting job so i dont screw up, and any tips for not hitting the valve seats? Im loving the intake, and im jealous of the 250 head and the carb, but ill make use of what I got.

 

I usually just risk it all, but I suppose you could wrap tape around the non-cutting parts of the dremel tool and maybe some clay or silicon or something for the seats.... Something easy to remove.

I know something I tried to stick to was turning the dremel off before removing it from the hole. After hours n hours for a few days, its hard for me to always have that much self-control though. [img]i/expressions/face-icon-small-happy.gif[/img]

The 32mm carb isn't too terribly expensive http://www.bikebandit.com/product/A3309603 but I have no idea if its an improvement over the 28mm or not. I know the 28mm is better than the stock 26mm. I should know more tomorrow after the first test ride with the new setup. If it sucks, I'll have no choice but to go with forced induction or else have a junk head.

You might find a 250 on ebay if you keep watching for a while. That's where I found mine. The 250 looks exactly the same as the 230, but has a larger rod, wrist pin, taller jug, higher duration cam, larger intake valve, better shaped ports, straighter exhaust header, 7 clutch plates instead of 6, and 4th gear is closer to 3rd in ratio. The downside is its heavier than the 230 and the timing is not as advanced. I used the flywheel from the 230 to put my timing back at 35 degrees BTDC instead of 32 BTDC.

Try not to be too jealous though.... I've been throwing money at this thing for over a year and a half! And I'd hate to know how much time I have wrapped up in it. [img]i/expressions/face-icon-small-shocked.gif[/img]

 

RANDY! WOW, just WOW!!!

I had my suspicions about you, but, DAMN!!!!!!!!!

Talk about a whole nother level???? Fu@kin sweet!!!!!!!!!!!!!!!!!!!

 

Let me know how that test ride goes

 

<div class="FTQUOTE"><begin quote>Originally posted by: PoolGod230

RANDY! WOW, just WOW!!!



I had my suspicions about you, but, DAMN!!!!!!!!!



Talk about a whole nother level???? Fu@kin sweet!!!!!!!!!!!!!!!!!!!</end quote></div>


Well.... Its a special carb. Only the best! [img]i/expressions/beer.gif[/img]

 

Btw, if you ever get a KN filter, get the pre-charger. The dirt just fall off that thing! Only mud will stick. Dust just wipes or blows right off. I know the price of them can be kinda shocking, but if you're paying $50 for a filter that's supposed to last a lifetime, you really should have the whole system. Amazon.com has about the best prices and shipping is always super fast from them.