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wppracing-tech/mod page

Technical Modification Page
& How To Guide

 

 

Click any image to enlarge
 
Call with any questions.
 

 
       KOSO WIDE BAND AIR FUEL METER
                         

                                   Short Video clip of sensor working

                                           watch-v=6BMPIgho9Us

1. 2004-2005 model remove seat. remove tool kit and owners manual. This will allow you to install a small 12v battery in this area. 2006 - up use OEM battery and location.   2. Find a location to attach /mount the digital display.   3. Install the wiring and attack it to the battery. You will need to made a ground wire for the battery and install attack it to the subframe. Also the power wires will have to be made longer to reach the back. I installed a switch to control the power.   4. Remove the exhaust head pipe and locate the location for the bung fitting. Drill and weld the bung into the head pipe. The directions recommended 200mm from the opening of the pipe.  5. Remove bung plug and install the BOSCH O2 sensor and secure the wiring out of the way.   6. Turn switch on and make sure display works. You can set a lean condition / rich condition warning or leave warning off. Came with detailed instructions.   7. Start engine and make sure display reads. Here is the reading at idle.
 
             REPLACING A CAM CHAIN
                  04/05 TRX450R

                                        
                                                     


1. Remove rear fender, gas tank and splash shield.. 2. Loosen cam chain tension/remove tensioner. 3 .Remove valve cover and cam sprocket. 4. To remove chain guide, drain coolant and oil. Remove cylinder head. 5. Remove oil cooler line and side cover bolts. 6. Remove side cover and set aside. 7. Remove flywheel nut 19mm and install thread protector. 8. Install puller and remove flywheel
9. Remove left chain guide and inspect. Remove the oil strainer plate and remove chain.
WPPRACING CUSTOM AIR INTAKE SYSTEM

 

THIS IS A ESR INTAKE WITH A CUSTOM BILLET ADAPTER FLANGE. THIS INCREASES THE FILTER ID FROM 3 IN TO 4.5 ID. THE OEM AIR BOX ALSO CAN BE USED, BUT WITH NEEDED MODIFICATIONS TO IT.
     
WPPRACING / K&N AIR FUEL SENSOR INSTALL
THIS IS A SIMPLE TO INSTALL A/F SENSOR THAT WILL ALLOW YOU TO JET THE CARB INTO THE SAFE RANGE CLOSE TO 13.1. THE SYSTEM REQUIRES YOU TO DRILL AND WELD A SENSOR BUNG INTO THE HEAD PIPE. INSTALL THE METER AND CONNECT TO A 12V SUPPLY.
     
WPPRACING CUSTOM PIPE THIS SYSTEM USES A ESR HEAD PIPE, RAGE/DASA MID PIPE AND A WHITE BROTHERS XCR SILENCER
     
HONDA TRX450R
AIR LID MOD
THIS IS THE OEM LID WITH THE TOP REMOVED. IT IS COVERED WITH AN OUTERWEAR PRE FILTER .
     
HONDA TRX450R
AIR BOX WITH CRANKCASE VENT FILTER

 
  WHEN USING AN  AFTERMARKET FILTER, THE CRANKCASE VENT TUBE IS FILTERED AS WITH THE OEM FOAM FILTER. INSTALLING A K&N VENT FILTER CORRECTS THIS CONCERN
     
HONDA TRX450R
AIR FUEL MIXTURE
SCREW ADJUSTER
THIS TOOL MAKES MIXTURE ADJUSTMENTS SIMPLE . THERE ARE 16 CLICKS PER 1 TURN
     
CAMBER ADJUSTMENT
TOOL
THIS MAKES CAMBER SETTING
SIMPLE AND EXACT.  IT CAN
BE PURCHASED AT  LOWES FOR UNDER $10.00
   
 
WORKS TRX
TRIPLE SPRING KIT
CLICK ON PICTURES
TO ENLARGE

 

     
JE 13.8:1 PISTON
INSTALLATION



click on pictures to enlarge.
Remove the rear fender and gas tank. Drain coolant. Remove exhaust. Remove cam tensioner. Remove cam sprocket . Loosen the air box assembly and carb manifold clamp. Slide assembly back until it clears the manifold. Remove cam assembly. Remove head hanger plates.
Remove head and cylinder nuts and bolts. Remove head.
Remove cylinder. Remove piston.
You MUST use race gas
 
     
DASA Head Pipe Bead Blasting
 
The pipe comes in 304 SS . I glass beaded it to give it a different finish
     
     
BALDWIN 14.1 Piston
This is the highest compression stock bore piston made so far. Baldwin Motorsports has them in stock
     
Baldwin Dual Valve Spring Kit This is a MUST when using aftermarket ignition systems that have an increased rev limit. I currently use these springs with the Baldwin 14.1 piston and Megacycle X2 cam.
     
DASA Filter Modification

 located a filter with a inner cone/vortex. I removed it and installed it into the DASA Filter. This mod should result in an increase in air velocity and a slight HP increase.
     
     
     
PWC
section
 Speed Plate Mod
R&D Plate and Riva Plate with Mod


 

The Speed Plate Mod netted a gain of 1.1mph . Depending on water condition speed gains will be between .5 and 1.5 . Results WILL vary  depending on your ski., weather , water condition , and riding style. You WILL gain more SPEED with this mod.  

      
 Blueprinted Intake Grate

Stock R&D Intake Grate ,  Modified Intake Grate

 

 Blueprinted Intake Grates allow optimum performance over a standard grate. This  consists of removing imperfection and sharpen/straightening of the scoop and trailing arms. All critical water flow areas are smoothed and refinished.
New  Blueprinted Pump
With  Mod



New OEM Pump with  Vein Mod
 

 
Starting with a NEW  pump  The  inner surface is modified to improve water flow.   The leading vein edges are reworked and the complete pump assembly is refinished. This allows MAXIMUM pump hook up in ALL water conditions. A must for Racing applications.
 
     
Yamaha GP1200R / 800R
Cylinder Port Shapes

These pictures show the difference between a 1200 and 800R cylinder .
**Note you can use the 800 cylinders on a 1200 and gain performance when using triple pipes**
     
R&D Free Flow  /  Riva Free Flow

R&D Free Flow Tube Installed

 
 

The R&D is a better design and a cleaner looking item once installed. The water box exit is 4in dia, the inlet on the R&D is also 4in dia. The end of the tube is 3 in dia so you only have about 2 inches of  3 in dia. If you already have the Riva tube installed you will need the original rubber tubes that you had before cutting to fit. You need the 4 in piece.

     
 Battery Relocation

 (1.) Remove the battery ,fire extinguisher and CDI Box. (2) Cut the area that holds the battery from the stock container.(3) Remove the rubber attaching parts from the box. and attach battery box. (4) Clean the right corner and secure the box to the hull with epoxy and stainless steel screws. Apply silicone between the box and the side of the hull to help reduce vibration.  (5) Install the battery and reroute the battery cables- you will have plenty of cable. (6) Remove the excess material from the stock box. (7) Install the fire extinguisher .
 

 

     
Carburetor High Speed Adjuster Access

 

.This will allow access to the mixture screw at #2 cylinder. Using a 2 1/8in hole saw drill through the pipe bracket.

     
Water Box /Free Flow Kit Installed

Rotate the water box so the outlet is at the 10:00 position. This will allow you to install the Free Flow Kit easier.

     
GP1200R Engine Damage This is a picture of my engine(08/18/02). The piston broke and hit the gas valve and took out the head, cylinder, piston, rings and gas valve.
     
Yamaha GP1200/800R Stepped Sponsons This mod allows the sponsons to be adjusted into a more aggressive setting. To perform this mod elongate the mounting slots. The center mount is a pivot for the other mounts. Set the front of the sponson in the up position and the rear in the down position. This will cause the nose of the ski to sit lower in the water causing a decrease in porpoising .
 Instead of stepping just set the sponsons in the down position.

 

     
Yamaha Impeller Removal

This is the fastest way to remove your prop. All the downward force/energy is being applied to the prop . It takes less than 1 minute to remove the prop from the shaft.
Removal Instructions : Put prop tool and wrench onto shaft. Install shaft holder / pump assembly into vise and tighten. Rest the pump onto a jack stand. Use a 3-4ft. pipe and place over the wrench. Pull down on pipe and remove the prop.

     
Different Location Factory Pipe Water Manifold This is how RIVA YAMAHA mounts the Factory Pipe Water Manifold . 
     
Broken Flywheel Pictures

These are pictures of a GP1200R Flywheel. When looking at the other side of the flywheel it doesn't show any signs of damage. REMOVE it and look at the other side. Symptons pointing to a flywheel concern- the ski feels like the timing is retarded , loss of power , intermittent spark , ski will run on trailer but not in the water. When replacing your flywheel you MUST lap the flywheel to the crank. Apply a small amount of Permatex Valve Grind Compound to the crankshaft end and rotate the flywheel. This will match the flywheel hub to the crankshaft .

     
Factory Pipe Left Front Motor Mount Modification This is a must when installing Factory Pipes. You must trim the front of the left motor mount bracket for increased clearance. If not the middle pipe will rub and wear a groove into the pipe chamber.
     
Novi Fuel Pump Line Routing When using Novi fuel pumps it is recommended that all of the pumps are looped together . This will allow the bad pump to get fuel from the other good pumps.
     
Tamper Cap Removal
Removal Instruction :  Remove the exhaust pipe to gain access. Remove the exhaust bracket and drill access hole in it. Drill a hole in the tamper cap. Using a small dent puller thread the end into the hole in the tamper cap. Slide the hammer up and cap is removed. Repeat for all the other caps. I remove the T part of the t - handle and cut a small slot in the end of it. I then use a thin screw driver to perform adjustments. Some people choose to have the T left on the adjuster.
     
Riva Stinger Water Filters

The Riva Stinger Water Filters are worth the investment. They filter the water before it enters the stinger jets on Factory Pipes. This will help prevent the jets from becoming clogged and overheating of the pipe/couplers.

     
Gas Valves Installed On a Single Pipe GPR

 

 

Take the manifold and attach it to the cylinders. Mark and grind the area that rubs the valve. Assembly the front gas valve. Attach the head pipe and mark the area that touches the valve . Remove the pipe and grind to gain the necessary clearance for the valve. Also grind the valve cap for clearance. Fitting the head pipe takes the most time to grind. Do a little at a time.

     
GP1200R Water Leak In Pump Well/Tunnel

Here is the water leak that is filling the ski with water. Pump pressure has caused stress cracks in the tunnel area and forcing water into the rear of the ski.  Picture 1 and 2 show the crack and 3 is the beginning of the repair.

     

RIVA Set Back Prop
YF-CD-13/19-SB
 
Pictured is Rivas new set back prop.
When it was first installed it hit the hub. Since then I made a 2.20mm shim to allow enough clearance between the prop and the hub. It is now so close it looks like it will rub. It doesnt. Testing after installing a washer to make it work( 1/8 in gap ) produced a top speed of 76.6 @ 7960. I will test again and be posting the new top speed since it is set back correctly.
Went  testing today, 8/11/02, and after setting the prop back correctly it ran a peak speed of  77.8mph @ 7980 - 8010rpms
Testing was done on MY 2000 GP1200R SS
     
GP1200R Power Valve Failure This is a picture of a GP1200R OEM Power Valve. The ski had 67 hrs on it and still ran fine.   The valve parts were resting against the Cat Convertor. This person was very lucky that the only parts damaged were the valve and piston/rings.