Another 530 kit install

[ThunderPaw]

I installed the 530 kit (from Motorsportz) on my 08' 510 about 6 weeks ago while i had the engine out to replace a failing cam bearing. As a data point, the stock piston and cylinder looked GREAT, with ring gap in spec. at 10,000+ miles. The 530 kit adds very noticable power accross the RPM range and is most welcome down low. I expect fewer hot stalls in the tight stuff when i get back off road. Suprisingly, viberation is no worse and may even be a little better. I also did some mild porting to soften the casting seams and a mismatch at the intake to port seat. Very easy to do safely with the right dremel bit. Very happy with the modification: Down side... tires go to rubber dust land that much quicker!

 

[MXRider]

Sometimes I wish I had gotten the 510 instead of a 450.

 

[Fast1]

Did you change (increase) the fuel metering or leave it in stock configuration?

 

[ThunderPaw]

fuel metering

Yes i put it on ibeat and reset TPS and FB1 (they were way off). At first i matched the FB1numbers (at about 102%). It occasionally popped mildly on decel. if cold temps. I bumped up the FB1 to 103% and haven't heard a pop since. The 08's don't have the same adjustability as later models.

 

[Motosportz]

Nice writeup / info, thanks.

Kelly

 

[J.R.]

I also did some mild porting to soften the casting seams and a mismatch at the intake to port seat.

What do you mean there? Are you referring to the rubber boot between the head and carb? I noticed it was a little mismatched when working on mine.. Looks like it has some room for improvement

 

[ThunderPaw]

Reply to JR

Yep, when looking into the mounted rubber boot, i observed a metal mating surface width of about 3/32" extending about a third of the way around the port. It looked like turbulence would be introduced as incoming air hits that "shelf". Of course you never really know but that one imperfection cancels out another, but just the same. I also sharpened the split between the two intake ports being very careful not to lower it further back or go too thin so as to crack under expansion. A casting seam runs right through that split, though not messy i thought a sharper delineation would be benificial. Thankfully, it does not whistle, as i feared it could. I don't really know what i'm doing, it just seamed intuitive to my thinking that those small changes couldn't hurt.
There is a dremel bit that is round or wheel shaped and of a little smaller radius than the ports. It looks sponge like but is very abraisive and cuts at a safely controlable rate and leaves a kind of cross hatch like surface texture. It worked very well for me for all of this work.

 

[J.R.]

sounds like you are thinking on the right track Thunderpaw

Got a pic or link to a similar dremel bit? Sounds like one of those ceramic style ones.. I think I might actually have one.. Hmmm...

 

[ghte]

Good update Thunder, cheers for sharing

 

[meeh]

Yes i put it on ibeat and reset TPS and FB1 (they were way off). At first i matched the FB1numbers (at about 102%). It occasionally popped mildly on decel. if cold temps. I bumped up the FB1 to 103% and haven't heard a pop since. The 08's don't have the same adjustability as later models.

With EFI you can't tell if it's lean by popping on decel! EFI shouldn't pop because it's supposed shut off gas completely when you've got the throttle shut. Just something to keep in mind. I've made the same error

If you can, measure A/F on a dyno (or alternatively if you can sort out the fuelling by going the PCV /w AT route) for peace of mind.

 

[ThunderPaw]

Reply to JR

These guys (from Dremel site):

511E EZ Lock Finishing Abrasive Buffs - 180 & 280 grit (2 Pack)
Great for cleaning and light sanding. Use on metal, glass, wood, aluminum and plastics. For use with the EZ402 EZ Lock Mandrel or Standard 402 Mandrel.

Should be a picture attached: