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Old 03-10-2011, 10:35 PM   #1
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272 cam Install head porting questions.

OK so I have a freshly rebuilt 1.6 8v. I picked up a Cam from Zack at Zukiengines.com (thanks Zack!).

I am going to port the 1.6 8v when I have the head pulled to install the 272, it's not a regrind but a new cam.

Does anyone have any tips or pointers for porting the 1.6 head when adding a cam? I know there is supposed to be improvement found in porting the exhaust side, is there anything specific to look out for or cuts not to make?

How about the intake side? Is it a matter of just keeping the radius symmetrical, or should the entire port be enlarged.

Last the TBI intake, is there any gains to be had here by doing more than just clean up of the casting.

I am open to any and all advice, and I welcome any comments and suggestions I can get. If the knowledge something a guy doesn't want out on the internet, I'd welcome a PM and keep it to myself.

Thanks up front for any tips and advice.

--Sky

Last edited by skyman; 03-10-2011 at 10:42 PM.
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Old 03-10-2011, 11:14 PM   #2
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Old 03-11-2011, 06:45 AM   #3
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Myself, espically about the intake...
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Old 03-11-2011, 08:13 AM   #4
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LittleBlackSambo on pirate is your man. He did a real nice writeup on heads.

He also was the guy we were working with for awhile on the supercharger idea.
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Old 03-11-2011, 08:25 AM   #5
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I see I'm too late. You already found Sambo
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Old 03-11-2011, 02:10 PM   #6
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Yeah i rad his thread, and looked at what he had, I got some good info out of it for porting. I was wondering if anyone who done a few of these had any specifics for the 1.6 head, or suzuki heads in general.
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Old 03-11-2011, 02:25 PM   #7
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I don't have anything to add to his stuff. I just port matched the intake to the gasket about 1" deep. Did nothing to the exhaust although I could see taking out the bump just past the valve on both sides. Plenty of meat there that I could see removing but at the limited RPM's I am running, or hope to be, I don't see the need for allot of extra work. I doubt it will see 7200 too often with my stock cam, valve train and exhaust system.
Sorry bud.
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Old 03-11-2011, 03:19 PM   #8
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No problem, any, info is good info. If I collect a little bit from a lot of sources I will be well armed.
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Old 03-11-2011, 03:30 PM   #9
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I meant to say thanks in there somewhere, and missed the point,. Thank you KB!
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Old 03-11-2011, 04:20 PM   #10
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Check with riev zuki. He did some something like what you're doing with a 1.6 he had sitting around.
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Old 03-11-2011, 06:01 PM   #11
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porting is really all about making the surface as smooth as possible and to gasket match ... make the ports the exact same size as the holes on the new gasket so that way the flow doesn't hit a bump or ridge ... invest in some dremel bits you will need a lot of them ... a buddy of mine also used polishing compound after he got his smooth.. gotta make sure you really clean the ports out after you use it ...
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Old 03-11-2011, 06:34 PM   #12
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Yep. I have done a few manifolds, and port matching on heads before, but since i have the head off I wanting to port as much as I can to gain as much as possible from the little 1.6 head.
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Old 03-11-2011, 07:01 PM   #13
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I worked in a head porting shop for several years, J&S Porting. Don't need to get carried away with polishing compound. Never even heard of it before. We did spend more time on exhaust getting it smoother than the intake but just sanding cones 80 grit is more than fine.

Port matching it most important.
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Old 03-11-2011, 07:08 PM   #14
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So port matching is important, casting flash..off the sides.

Is it it also important to keep the port size the same all the way from the intake tot he valve? or should it taper down in size as it nears the valve?

I am sure with most heads there will be the obvious flow obstructions and stuff. Sarge walked me through porting the carbed intake, and there was a lot more to that than one would think, to get it it flowing right.

I am under the assumption that porting out a carbed intake could significantly increase the top end power of a my-side or myside-II. Theres' a couple of spots in there that are very restrictive, and one would think it would really hurt the top end performance (which is where the HD carb could use some help).

I am glad I read the LBS thread. I will be taking out the little brass pipes or air injectors so I can do a better port job. I am curious how much it is worth, just taking those little brass pipes out of the intake stream.

With your quad carb setup, you know how much of a difference a good flowing intake tract can be! Double HP with the those carbs, they must really kick the 1.3 in the ass.
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Old 03-12-2011, 06:31 PM   #15
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are you done yet?
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Old 03-12-2011, 06:46 PM   #16
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I am glad I read the LBS thread. I will be taking out the little brass pipes or air injectors so I can do a better port job. I am curious how much it is worth, just taking those little brass pipes out of the intake stream.
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2% on super flow.
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Old 03-12-2011, 07:11 PM   #17
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Thanks fastspec, anything else to look out for when messing with the head? elcoem todrop me a PM if you feel like it
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Old 03-12-2011, 07:17 PM   #18
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Heheh not even close yet. Hey Zack, is the valve lash any different with the new cam, or just stock spec? Any numbers for timing, or the same as I usually run?

While I have the head off, would your recommend shaving say .010 (maybe a couple thou more say .012) off the bottom for a little bump in compression? Or should I just leave it stock, slap on a new Head gasket and call it good? The head is in great condition right now.. so I don't know if it is worth it or not.

BY the way the cam is just beautiful.. I Love freshly machined parts








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Old 03-12-2011, 07:42 PM   #19
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I am glad I read the LBS thread. I will be taking out the little brass pipes or air injectors so I can do a better port job. I am curious how much it is worth, just taking those little brass pipes out of the intake stream.
what are they for? just curious...

i also want of port mine..
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Old 03-12-2011, 07:56 PM   #20
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I believe they are to either insert fresh air into the cylinder to promote better mixture/burn, or they are here EGR dumps ports. They call them inductor nozzles. I am pretty sure they squirt air into the cylinder.

Little Black sambo did an excellent write up on Pirate about drill tapping, and plugging them with brass screws so they could be ground down and ported through. even if it is air, I am pretty sure it's an emissions thing.
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Old 03-12-2011, 09:47 PM   #21
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Arnt those for the egr system...Im wondering because of where they are placed if it would do anything for cooling the exhast valves.. It does use exhast air though. But maybe it cools enough to help.. Mine are all gone but I dont think they were filled with brass.. Or at lease it doesnt look like brass...

The place I had do my head a couple years ago also bench flowed it.. They claimed it would make a huge improvement.. But I did so much crap to that poor little engine I cant tell what made the biggest difference..

Also in the future if you happen to replace an intake or exhaust gasket your gonna need to match the gasket again.. I have seen a couple buddies forget a couple years down the road..

Years ago I had a a guy that went by the name Sarge make me up a custom manifold and do some mods to a weber and while im quite sure the weber had nothing to do with it mainly because it was on before the intake mod but it was a night and day difference just having it intake hogged out..

I dont think he as advertising them any more but I do still have his info it someone needs it. He did good work but havnt that was years ago I had him do that for me.. I still talk to him ocasionally through e-mail..

Im fairly sure it would help on the harley carbs though.. Any thing has to be better than stock on those intakes..


Hey gecko, that minifold you make blocks those doesnt it? Would it make a difference either way? All the heads I have ever taken off had the passage blocked with carbon or burnt oil residue anyway..

Last edited by badzook; 03-12-2011 at 09:55 PM.
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Old 03-13-2011, 02:50 PM   #22
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I believe they are to either insert fresh air into the cylinder to promote better mixture/burn, They call them inductor nozzles. I am pretty sure they squirt air into the cylinder.

Little Black sambo did an excellent write up on Pirate about drill tapping, and plugging them with brass screws so they could be ground down and ported through. even if it is air, I am pretty sure it's an emissions thing.
We have a winner I use mine for injecting nitrous . Sounds like you have the right idea/direction for porting.
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Old 03-13-2011, 02:55 PM   #23
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Heheh not even close yet. Hey Zack, is the valve lash any different with the new cam, or just stock spec? Any numbers for timing, or the same as I usually run?

While I have the head off, would your recommend shaving say .010 (maybe a couple thou more say .012) off the bottom for a little bump in compression? Or should I just leave it stock, slap on a new Head gasket and call it good? The head is in great condition right now.. so I don't know if it is worth it or not.

BY the way the cam is just beautiful.. I Love freshly machined parts

I would only take off whats neccessary to clean up the head surface. (not the way to gain Comp.) Unless you have an adj. cam gear. And can dial in the cam. Which you will need the spec's for. Did the cam not come with a spec sheet? Hard to belive that a perf. cam doesn't have the timing and valve adj spec's with it.
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Old 03-13-2011, 03:14 PM   #24
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I didn't see one in the box, it's possible that it came attached to the outside of the box in the packaging and I haven't found it yet.

I am all for buying, or having a adjustable cam gear made if it is going to help performance.

I guess my feeling on the samurai is this, I do not want to start down the road of heavier engines,needing heavier transmission, and then a heavier case. I like the Suzuki power plants all the way up into the 2 liters. My theory is to squeeze as much power as I can out of the little 1.6. if that means an adjustable cam gear is needed I guess I will have to go that way (hoping I don't).

If there was a way to get higher compression pistons in the 1.6 block without having to order them custom made, that is the route I would like to take.

If I am missing any obvious ways to squeeze some juice out of this little one-sixer, please enlighten me. I know these things can make the power without having to order custom made parts, I just don't know how to do it.

The nitrous idea is rockin! I would'a never thought of that. That puts the nitrous right in where it needs to be

Thank you Rieve Zuki, for taking the time to answer, I appreciate it.
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Old 03-14-2011, 10:11 PM   #25
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? Hard to belive that a perf. cam doesn't have the timing and valve adj spec's with it.
the instructions cost extra!!!!



in all seriousness I'm not sure why the sticker is not on-top the box, I'll post one up here in a few.

1.3 Stage 2 cam specs.jpg

Stage 2 cam specs (RV2, 272)
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