RS Warrior Forum banner

122 CI Motor Build Thread

7.6K views 20 replies 12 participants last post by  yodie001  
#1 ·
As most of you know, I had a little accident with the Nitrous resulting in a bent rod. Motor has to come out, which is no small task! My first thought was to pull the crank and send it off to have it lightened and balanced with a set of Carrillo rods and put it all back together with the 110 parts. I wouldnt get any more power, it would just come on quicker. So I call PR and talk to Nigel a bit. Some how the 122 kit comes up and he says he has some parts left over from back in the day when they were building 122 motors. Cost of the parts was a bit more than what I had in mind, but the wheels are turning now none the less.

It would cost a lot of money for me to send my motor across the country and have PR do the build, so I decide to find a local guy to do the machine work. Before I talked to Nigel I called Carrillo to find out about the rods and they gave me a number of a performance shop 3 hours away from me. I got a price on the rods from them. Then after talking to Nigel I decided to call this local shop back and see if they could recomend a machinist to do the machine work. So I start to tell them that I am thinking about doing a crazy build and need some custom machining done. Turns out that this shop has done 122 CI Roadstar motors before!!!!! JACKPOT....someone that knows exactly what needs to be done!!!!

I remember reading on here when PR and Orient Express were doing 122 builds it was costing over 6k...maybe even closer to 8k. Which to me seemed crazy. With me pulling the motor myself I will be right around 3K. Pulling the motor and splitting the cases is no walk in the park. I don't ever want to have to do it again! This is definitely the time to do a big motor if ever there was a time. I pulled the motor tonight and am dropping it off at the builders shop on Sunday. It sounds like Carrillo takes 4-6 weeks to build a set of custom rods, so it will be awhile before I have any more info on this build.

Here are some pics of the chaos.

Image
Image
Image
Image
Image
Image
 
#6 ·
I thought they stopped making the 122 due to over heating issues.

Sent from Motorcycle.com Free App
Posted by Reeza back in 08...

Image
Re: 122 cubic inch kit
I have the 122cuin kit on my bike and the best numbers we got on it was about 132Hp and 151ft-lbs. But I am running wide open speed star velocity stacks with no filters. With a filter on expect 3HP drop. My bike is geared tall, I have the 33 tooth front pulley and the 280 and the road star 5th gear. None the less the bike pulls extremely hard. Nigel's cams are really good for mid range and top end.

You do nto have to go all out, you can get the 2.0L kit plus pipe and PCIII and the air filter kit and you will be very happy... I have not had any problems, the bike starts and runs extremely well.

We have done about 4 of these kits so far including my own. So far very good, with no issues. Nigel did change the lifters as the early ones made a lot of noise, the newer ones are much better.

If you are in a hot climate, I would definitely go with the oil coolers. They are good for at least 25 degrees on hot days.

Ride Safe & God Bless
 
#8 ·
Yeah, I talked to Reza about the 122. He said he did not recommend it if you would be in a lot of stop and go traffic.

Good luck with your build. Will you be adding Nitrous back to the mix, since you are using stronger components? I look forward passing you in my car one day.
 
#12 ·
The rods are definitely custom, made to order. Not sure about the rest. PR told me he had a set of rods on the shelf and possibly the pistons. I will say his prices are a bit steep though.

I called OE the other day to see what their thoughts were on cams for the 122...they said they haven't made cams for the warrior in 5-6 years...the sad truth is that there isnt much going on with the warrior these days, as far as custom motor work. I didnt ask about the 122 kit availability...but I would guess that they dont have the parts on the shelf.

If my build goes well I will let you know who did the work and the final price. Remember though, I already have head work and speedstar cams....both of which are highly recommended for this build, so you would want to add that to the price.
 
#14 · (Edited)
all the parts all the places like patrick, oe, and such used were out sourced from other high end dealers ,like carrillo,je pistons, and cams recut thru large cam companies. so everything would still be available if you contact these or other companies that worked the the above mentioned pr,oe, . btk572
 
#15 ·
all the parts all the places like patrick, oe, and such used were out sourced from ofther high dealers ,like carrillo,je pistons, and cams recut thru large cam companies. so everything would still be available if you contact these or other companies that worked the the above mentioned pr,oe, . btk572
Exactly, that's why I am able to do this much cheaper than what guys have done in the past.
 
#17 ·
I finally got my motor back from the machine shop this summer. I started to assemble everything, then discovered that the piston skirts were hitting each other. Took the bike and all back to the machine shop and basically told them that this was their baby now... If there were going to be any other issues, I wanted them to be responsible.

I get the bike back and the guy that assembled the engine said that he added a shim/base gasket (which dropped compression about .5, maybe even a whole point, depending on if he used a .02 base or the .02 and the .01 together) Kinda disappointing to me, I sent the bike with a .01 base gasket, and that was getting me to about 10.25:1, then he changes it out for some reason.

So, bring the bike home and finish installing valve cover, throttle bodies, etc. Fire it up, it runs like crap. Get the auto tune up and running and do several rides trying to get the tune dialed in. Never really get it to run all that great.

Take it to a dyno tuner. Dyno guy is having issued getting it to run well. He orders a set of Bosch injectors. (I had a set of 660cc injectors in the bike...guy I ordered them from is the one that recommended the size...he said if I am doubling the oem hp then I need to double the injector size...I don't know why I listened to him, but I did)

New injectors, and it is running pretty good. It still acts a little temperamental, especially on warm up. Bike only makes 110/130. I am disappointed. I was hoping for closer to 125/150 or more!!!

I get the bike home and perform a compression test. Rear cylinder is WAY low. Turns out that the valves were adjusted too tight by the guy that assembled the engine.

Reset the valves...I immediately notice how well it idles, much less finicky at startup as well. So back to the dyno we go. New tune, rear cylinder tune changes quite a bit. But still only making about 110/130.

Bike runs good, but it is not putting down its potential. Now I am contemplating tearing into it yet again, hoping to wring out the last few HP...for some damnn reason good enough is never good enough for me!

I have since bought a Speedstar ECU...however I might be better off to send my ECU off to Ivan for a custom program.

When I was doing the compression calcs, I CCed my heads and was coming up with about 102cc, but everything I found on here says Warrior heads should CC out at 97cc. Summer was half over at this point, and my bike had been in pieces for2 years, so I said the heck with it and rolled on.

I also need to get with Nigel and see how much compression these cams might be bleeding off. With the thick base gaskets, large head volume and big cams, its possible that I am only running about 8.5:1 or even lower.

If I get the compression up closer to 10.5:1, add a little timing and bump the redline, I should be able to get the 125hp I was hoping for.
 
#18 ·
It will be awhile before I do anything else with it. The bike will be on the back burner for a bit. Snowmobile season is on the door step...getting the sleds ready. Finishing up a SRX build...got to love a 15 yr old machine that will smoke any of the new junk... LET IT SNOW!!!!
 
#19 ·
WOW!... that was quite a story of clusterfu$ks from the assembly guy!! WTF??

sorry you having all these issues. It's stories like this that terrify me about modding my engine...

Please keep us informed and updated when you jump back into this $hit salad...