Boyesen Rage Cages tested on a trail-mod Etec 800 Dyno testing and text by Jim Czekala

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1 Boyesen Rage Cages tested on a trail-mod Etec 800 Dyno testing and text by Jim Czekala Boyesen marketing guru Joe Nocentino came to DynoTech Research to test their reed cages on The Unknown Trailrider s modified 2014 Etec 800 (he was the fellow pictured on Jim Czekala s Facebook page next to his sled with a cardboard box on his head with cutout eyeholes ostensibly to hide his identity from the pals he rides his bone stocker with one wise FB friend referred to the as thinking inside the box! ). As seen on this website, the Boyesen Rage Cages worked well both on the Etec stocker and the Crankshop trail mod, but Joe was annoyed by some internet chatter that suggested stock reeds were dyno testing best on the modified Etec 800s, and wanted to put that to rest. This Etec 800 was trail ported by D&D, and also has a custom Y pipe with a larger outlet and sealing donut, and a stock pipe modified by replacing just the stock donut flange with a larger one, and a Power Commander V fuel tuner. The Etecs are tricky to dyno test properly coolant temp seems to like to be between 100 and 125 F to be optimal, and muffler temperature for all good tests ranged from F. Today we had Jim Cooper from Cooper Sales and Service in Waterport, NY using his BUDS computer to monitor both temperatures to ensure good repeatability (+ or 5 degrees coolant temp) as well as noting deto and any adjustments that the ECU might make to eliminate the knock. Today, the sled s 93 octane fuel measured 91.5 R + M/2 and 6.5 % ethanol when tested with our Zeltex ZX101C octane meter. Today, with 3000 miles on it and timing set at +1 and testing done on a humid spring day, we baseline tested the well heat-soaked (hot crank and cases) engine with stock reeds at HP. TRAIL MOD ETEC 800 STOCK REEDS, FUEL ADDED WITH PCV EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B DenAlt Air_1c FulPrA RPM CHp Clb-ft lb/hph lbs/hr Ratio Feet CFM psig

2 Next, Joe installed a set of production Boyesen Rad Valves and, like we saw on the Crankshop modded engine, airflow and HP were significantly increased as they were on the CrankShop engine two HP at peak revs, and four HP in the midrange. It should be noted that we had to add fuel with the PCV because the Boyesen reeds high airflow resulted in too-lean A/F and possible power drop. That might explain why people with un-instrumented dynos might be fooled into thinking that higher airflow = lower HP. Or, even people with instrumented dynos can get fooled if they are not paying close attention to coolant and exhaust pipe/ muffler temperatures as well as A/F ratio and CO levels in the dyno room. Remember the Etec ECU can be as cantankerous as Goldilocks pulling timing, adding fuel, and even perhaps partially closing the exhaust valves to minimize heat and horsepower if coolant and exhaust temp is too cool or too hot! Both must be just right to obtain repeatable, optimal results, which these were. TRAIL MOD ETEC 800, BOYESEN RAD VALVES AND ADDED FUEL EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B AirInT Air_1c FulPrA RPM CHp Clb-ft lb/hph lbs/hr Ratio degf CFM psig

4 Now Joe was satisfied that the production Boyesen Rad Valves performed as well on the ported Etec 800 as they did on the CrankShop trailmod and the stock version. But he also had a set of prototype Boyesen cages fitted with Viton Oring material inserted into grooves machined into the cast aluminum cages (see photo below). The idea was to eliminate fiberglass reed damage occasionally caused by the reeds plastic coating sticking to overheated aluminum reed cages on Etec engines that spend a long time at WOT the Viton material should prevent heat transfer from occasionally overheated Etec crankcases to the reed petals. In addition, the Viton sealed cages were fitted with single-ply CarbonTech (Boyesen s proprietary true carbon fiber blend) reed petals for this test session. Now comes the most enjoyable part of the session. Joe Nocentino was hoping that his prototype Boyesen Rad Valves with Viton Oring seals and CarbonTech single piece reed petals would eliminate occasional overheating of reed petals and match the airflow and HP of the conventional Boyesen Rad Valves with fiberglass reed petals. But we were more than pleasantly surprised to see even higher airflow and horsepower al through the RPM band than the conventional Rad Valves produced, which required even more fuel to be added with the PCV tune. Now airflow is up a whopping 6-7% CFM over the stock reeds throughout the powerband and HP is higher (but by a lower %) with zero clicks of deto showing on the BUDS computer! Though he was delighted with the performance of

5 the Viton/ CarbonTech Rege Cages, Joe s opted to take the high road and reserve the complete test data until Boyesen homes in on the final production combination. Stay tuned! Ultimately with these prototype Rad Valves we were able to gain (over stock reeds) an amazing 6% airflow increase at peak HP RPM. But even more amazingly we picked up the midrange airflow up 7%. But as expected the HP % increase is somewhat less than the airflow % increase. What happens to the extra airflow that s not contributing to power? It s probably being short circuited a term referring to air going up the transfer ports and out the exhaust ports and escaping out the pipe not trapped by the returning sound wave. While we wish that we could trap all the extra airflow and use it to make more HP, it s conceivable that the extra short-circuited airflow might be a useful thing because it should serve to: help purge the combustion chambers of active radical gases that create detonation help cool the combustion chambers and hot exhaust system help reduce emissions as a % of total exhaust gases. Once again, shortly after we had that great success with the new rubber dampened VForce reed cages on the Polaris 800 CFI2, we saw incredible improvement in airflow and horsepower improvements with the new Viton dampeners/ thermal barriers/ seals on these preproduction Boyesen Rage Cages! Joe Nocentino likes to think that the CarbonTech reed material is the primary cause of the improvement. Kevin Cameron thinks the Viton is increasing airflow by preventing high frequency vibration at the reed tips. He commented: I wonder if the rubber, by damping out bounce and "tip whip" (vibration), retains more of what has been taken into the crankcase. When I visited S&S and we were looking at their Spintron rig, they told me that in the old days it was considered "acceptable" if a valve in a NASCAR engine bounced 5 times after closing. But when they improved their cam dynamics, they got the standard down to "only" three bounces KC At DynoTech Research we ve done testing and tuning on lots of full mod case reed carbureted race engines. Often, at peak torque and higher RPM we invariably see a cloud of standoff outside the carb inlets air/fuel mixture that has escaped from the crankcase intake due to reeds failing to close tightly. Could the petals be suffering from tip whip allowing a fair % of pressurized mixture to blow back out through the carbs instead of being forced up through the transfers picking up even more fuel along the way ( multiple carburetion )! Could these high-powered race engines similarly benefit from Viton sealed/ dampened cages? If we eliminate most of the multiple carburetion then we must jet way up before the first Viton sealed reed test. Remember when reeds fail to trap the air/fuel mixture in the crankcase it blows back out through the carbs picking up another load of fuel on the way. Then on the next intake stroke the standoff mixture goes through the carbs once more picking up a third load of fuel! Let s fire up those CNC milling machines and find out if we can trap all the good stuff and make the engines happy!

Before the Viton sealed Rad Valves become available Boyesen will have to determine the optimal combination for each of the applications that they currently serve.

6 Before the Viton sealed Rad Valves become available Boyesen will have to determine the optimal combination for each of the applications that they currently serve. (Etecs and other reed inducted engines). Joe Nocentino is planning another DynoTech Research session with a 2014 Etec 800 stocker to try Boyesen Viton sealed Rad Valve cages fitted with current double layer fiberglass reeds and others with CarbonTech reeds. Then will come endurance testing for reliability (Boyesen has a SpinTron-like motor driven engine that can put reeds through lengthy endurance tests). Stay tuned for further developments! Prototype Boyesen Rad Valves with Viton Oring material dampening/ sealing/ insulating the CarbonTech reed petal

einstein Tablet+ or einstein Labmate+ paired with a tablet Temperature sensor (-40 to 140 C) Plastic Bag Rubber band (to seal the plastic bag

einstein Tablet+ or einstein Labmate+ paired with a tablet Temperature sensor (-40 to 140 C) Plastic Bag Rubber band (to seal the plastic bag Have a look at the two pictures below: 1. What do the two have in common? Do they represent common experiences? 2. Try to explain what is happening to the kids in the pictures and how they are feeling.