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 ALBA 734 Big Bore for 2011 Rhino 700

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ChrisH

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PostSubject: ALBA 734 Big Bore for 2011 Rhino 700   Tue Mar 12, 2013 6:34 pm

Ok boys, I am bringing this thread on over so that you can check out my progress.

For the new guys: I am kinda nuts and decided to tear into my low mileage Rhino in the quest for MOAR POWER! I am not saying this is a How-To by any means, it is more a log or a journal of my progress. It's a place for me to get a lot of good, free, advice from you guys because this Rhino is really draining me, haha! So follow along, if you like. You might even get a laugh or two in, but please, don't laugh too hard. It's my first time in an engine.


Below are the pics of the new parts for the big bore kit. I already have a JBS sheave, gold secondary, Hotcams stage 1 Raptor cam, 46mm throttle body, Muzzys dual exhaust, and a MSD 3D.

Here is a pic of the CP piston. It is beautiful.
I put my phone next to it on the desk for a size comparison.



Underside of the piston



And here is a pic of the piston and new cylinder Alba sent me.





I started to gap the rings and check clearances.
According to the CP brochure that came with my piston, the top compression ring should be gaped according to this formula: (Bore x 0.0045") = ring gap

So for my build, my bore is 105.5mm, or 4.153"
4.153 x 0.0045 = 0.018" Top Ring Gap


You are supposed to determine ring gap with the rings inside the cylinder. So with the cylinder and rings bathed in motor oil, I proceeded to check and file. I used the piston to "square" the ring in the cylinder:



After filing for a while, checking, re-filing, and rechecking, I finally hit my target of 0.018" ring gap. Here is what eighteen thousandths looks like:





I am taking my time and working slow since this is my first time into a motor.
Here's the last pic of my Rhino 700. If I muck this up, at least I'll have the memories of 1100 miles of pedal to the floor action.



Here is where I started, I removed the engine cover. Gotta start somewhere, you know?



After draining the coolant, engine oil, I removed my 46mm Benchmark throttle body from the cylinder head after unplugging the various sensors and disconnecting the fuel line. I simply set the throttle body to the side and didn't disconnect the throttle cable.



This is a look down the intake track, into the cylinder head. You can see the valves. Cool!



Things start getting pretty involved at this point. I removed the exhaust (God love those Muzzys and their knuckle-bustin design) and the cylinder head oil delivery pipe. Don't lose those copper washers! I also removed the cam sprocket cover and the inspection ports on the lower side of the engine case. Now for my favorite part - putting the motor at TDC and making sure everything is in time before removing the cam sprocket and head.




I have run into a few minor setbacks. Here is the latest update:
The intake and throttle body are removed. The The coolant hoses are disconnected. The head bolts are about to be removed.



This is when I knew I was in deep... lol. The part you are looking at is the oil delivery pipe. It is the oil line that delivers oil to the top end of the motor.



Off with its head! The cylinder head lifts right off. Here is what the inside of my head looked like when I pulled it off.



The next part of the job is to remove the cylinder.



I carefully lifted up on the cylinder.



With the cylinder removed, I was then able to remove the stock piston from the stock rod. Be sure to cover your work area thoroughly with rags to prevent any parts from falling into the motor.



Here is a pic of the stock 102mm piston next to the new 105.5mm piston



This is where I started running into problems, however.
Laughing

I had a heck of a tough time getting the new piston clips into place. But I held my tongue just right. I said my curse words in the right order, and wallah, they snapped into place!

Then it was time to install the new piston into the new cylinder. I lubed everything well with motor oil and tried to get the piston into the cylinder. I failed! I worked at it for a half hour and failed again. I just could not compress the rings with my hands enough to get the piston into the cylinder. I failed so miserably that I ended up breaking the middle cast piston ring.

EPIC PHAIL!!


And this is where I had to stop:



No big deal. I swallowed my pride and put in a call to Nate at Alba and he hooked me up with a new set of rings. They are in the mail. I am going to use a ring compressor this next time.


But wait, there is more!
I was ok with breaking a ring. It really didn't bother me too much. I was just glad I didn't put it back together with the broken ring and then start it up. That would have been a kick in junk!

I decided to cover my motor up since it would be a few days until my new rings arrived. Nate was off with Alba wining some big desert race (I'm totally tongue in cheek here - congrats!) and I knew It'd be at least a week before I got parts.

But evidently, I would still be kicked in the metaphorical junk. I mad a stupid, stupid, stupid, stupid, [get the idea, lol] stupid move. As I was covering up my motor with rags, I knocked one of those cylinder head dowel pins into the motor!

No
It fell right into the side of the motor where the timing chain and stator live. I tried everything to fish it out, but I was unable. I ended up taking off the side cover.



So the good news is that I was able to find the lost part. I was able to inspect the stator since it was apart..
I'm sitting on go now waiting on the new stator gasket and the new rings. The parts should be here in a few days.

Thanks for following along in my [stupid] build thread!
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Tue Mar 12, 2013 6:43 pm

I will also add that James of JBS was able to convince me to do the stronger head studs after his little water pump problem. I contacted Weller Racing and got the upgraded cylinder bolts and the head studs since this thing is apart waiting on my new rings.

Nate from Alba did not say they were necessary but after doing some reading I coughed up the extra cash and got the stronger bolts.

Some guys on the GrizzlyCentral spoke negatively about the ARP head studs saying that they don't like being rapidly cooled in water- that the metal shrinks at a different rate and can allow the head bolts to loosen over time. They said the guys with Raptors go with the ARP studs because they don't dunk a Raptor in water like a Grizzly. My usage on a Rhino would certainly be such that it would get dunked in the water many times.

Can anyone confirm or deny this?
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Tue Mar 12, 2013 7:27 pm

Awesome build threat!! Excited to watch the progress and results. You are right about the cylinder bolts and head studs, this is something you don't wanna chince on. Make sure when tightening them you don't hit one side to spec then the other. Make sure you are evenly distributing the torque across all bolts and go in a criss-cross pattern. Good luck with everything, I'll be watching the progress!
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 13, 2013 5:08 pm

Great thread, Chris. Thanks for taking pictures, too!
Just take your time and you'll be fine.
Don't forget the loctite.
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 13, 2013 5:09 pm

My parts arrived today from Jason at Weller Racing.
These things were not cheap!!



It's head studs and cylinder studs. The directions say to torque the head studs to 45lb-ft. And good call, greeley; the factory service manual states that these bolts should be tightened in not only a specific order but also a two stage tightening process.
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 13, 2013 5:27 pm

thanks for sharing!!
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Fri Mar 15, 2013 10:34 pm

Looking good buddy im sorta getting jealous... hope you have no further issues building this beast.. good luck!!
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Sat Mar 16, 2013 12:41 am

Well, today I received my new stator cover gasket, as well as my new piston rings from my initial screw up! Heck yeah!



Unfortunately, I ran into a few issues when trying to gap my new rings. Right out of the package, the ring gap is already huge. This is a pic of the ring without any filing.




The next pic you see below is the proper .022" feeler gauge for the center cast iron ring, inside the ring as it came out of the package.



I called Nate from Alba as soon as I realized that something might be wrong. But he was not in the office. George from Alba suggested I email Nate, which I did.

I'm a little bummed because I wanted to get this motor back running this weekend. But oh well. I'll see what Nate has to say when he returns my email.

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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Sat Mar 16, 2013 1:51 am

thanks for taking the time to write up and share
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Sat Mar 16, 2013 9:58 am

wrong rings!!!prolly packaged wrong from the factory...seen it before..thats why you always check ring gap on any motor
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Sat Mar 16, 2013 9:59 am

check your piston to cylinder gap too
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Sat Mar 16, 2013 1:16 pm

Great build thread, It dosent just go together like lego's. Stay on top of it and you will have a monster to be proud of!
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Tue Mar 19, 2013 9:52 pm

great thread !! Thinking about doing the same to mine. thanks for posting learning alot from this thread.
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Tue Mar 19, 2013 11:28 pm

Just ordered the 734 kit from Nate at Alba this morning, so i will be whatching this thread closely also.great pics.

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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 2:05 pm

I received another package of piston rings from Alba Racing today. Unfortunately, they are, again, the wrong rings. I talked to Nate from Alba and he believes that there might have been some kind of mix up at CP.

Be sure to check and double check your rings when you get your big bore kit. My original ring upper ring has a red mark on the end near the gap. The original cast ring (which I broke) has two pink marks.

Both packages of incorrect rings have an upper ring with a one red and one dark orange mark. The cast ring has no paint markings.

This is super frustrating! I really want to get this thing up and going and twice now I've gotten the wrong rings. But I will also say that Alba has been more than helpful and shipped me rings very fast. They problem must be on CP's side. I will update this thread when Alba gets back in touch with me about the correct rings. Until then, I'm pretty much dead in the water.

~ Chris



rhinopg wrote:
Just ordered the 734 kit from Nate at Alba this morning, so i will be watching this thread closely also.great pics.

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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 2:38 pm

Bummer!!! I hope that CP at least overnights you the correct set to get you taken care of. Been in your shoes before and man is it a PITA!!
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 2:59 pm

Maybe if they see this thread they'll get their butts in gear!
There's nothin' a good businessman hates more than a bad rap.
They're not in business to mess up, it costs them $.

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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 4:21 pm

Agreed and agreed!
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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 5:34 pm

Nate from Alba just informed me that there was an issue in packaging over at CP. They are drop shipping me another set of rings for overnight delivery.

Alba Racing has been good to me in all of this, even though the initial broken ring was my own fault.

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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 6:02 pm


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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 10:27 pm

are you not done with this thing yet? lol im ready to see how she runs... might as well have the head ported with all this extra down time Smile

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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 10:46 pm

dang chris,hate you are having all these problems,but its a good thang that you are checking those ring gaps,otherwise u would be burning oil and not know why...its best to double check everything when building a rhino motor...most guys would have just slapped those rings in there without checking the gaps!!

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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 10:46 pm

You guys are a riot!
Trust me, I wanted to have the head ported and done up with the +1 valves. But the budget just couldn't handle it right now.

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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Wed Mar 20, 2013 10:48 pm

And by the way...great write up!!

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2007 rhino,720cc,Falicon super crank,JE 10:75:1 piston,stage 1 raptor cam,Bored Fcr 43mm carb,unifilter,muzzys,Jbs sheave and 14 gram Ods,orange spring,anti friction washers,slugged clutch,Jbs roof,Jbs radiator shields,jbs sticker=10hp,full windshield,siesmik doors,Se shocks,Summit heater,5000lb winch,Power steering,tach and guages,2 way radio,mp3 to 400 watt amp,4 polk speakers,4 Hid lights,alternator,and the list goes on!!


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PostSubject: Re: ALBA 734 Big Bore for 2011 Rhino 700   Thu Mar 21, 2013 11:36 am

Hang in there CrisH once you get that bad boy put back togeather you will be grinning from ear to ear when you mash that throttle.

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