Converting 135cc to 150cc block & piston set
- Thread starter CrescentScythe_86
- Start date
straight directly from Yamaha.. all about the benefits of DiaSil Cylinder and the difference between regular steel liner type cylinder :
ALL ABOUT DiASil Cylinder Link
according to yamaha, Diasil Cylinder just only began to deform (not 100% round because of wear) after 50,000 km usage, based on Yamaha Indonesia leaflet.. that's why your ENGINE GUARANTEE ONLY VALID UNTIL 50,000 km usage..
another link about Diasil Cylinder application for Yamaha YZF-R6
Yamaha Casts Its Lot with Aluminum Article at ALUMINUM NOW WEBSITE LINK
ALL ABOUT DiASil Cylinder Link
according to yamaha, Diasil Cylinder just only began to deform (not 100% round because of wear) after 50,000 km usage, based on Yamaha Indonesia leaflet.. that's why your ENGINE GUARANTEE ONLY VALID UNTIL 50,000 km usage..
another link about Diasil Cylinder application for Yamaha YZF-R6
Yamaha Casts Its Lot with Aluminum Article at ALUMINUM NOW WEBSITE LINK
some quote :
Development background
Cast steel liner type aluminum cylinder
The detrimental qualities of a cast steel liner type aluminum cylinder include the more complex manufacturing process, heavier weight and poorer cooling performance.
Plated cylinder
Plated cylinders are presently used on high-performance motorcycles engines, but the production cost is higher.
DiASil Cylinder
An all-aluminum cylinder manufactured with the DiASil Cylinder technology has no need for a cast steel liner or cylinder plating, which means a simpler production process. What’s more, it has the same outstanding cooling performance as a plated cylinder.
In general, motorcycle engines run at high rpm (10,000 ~ 20,000 rpm) and the resulting highrunning temperature makes cooling performance very important. That is why lightweight aluminum, with its excellent heat transfer rate, is used for motorcycle cylinders. These cylinders made of inherently soft aluminum have a cylindrical cast steel liner inserted along the inner wall of the cylinder to reduce friction resulting from the piston’s movement. Thus they are called “cast steel liner aluminum cylinders.”
This construction, in which a cylindrical steel sleeve is inserted along the inner wall of the cylinder, produces a cylinder which is very reliable from the standpoint of reduced friction and reduced possibility of engine seizure. That is why Yamaha uses this kind of cylinder on approximately 70% of all the motorcycles it manufactures. In the case of models for the markets of Asia and Central and South America, this figure reaches about 90%.
However, there are also problems with the cast steel liner type aluminum cylinder, such as the complexity of the manufacturing process involved in inserting the steel sleeve, the poor recyclability of these cylinders and the limitations in heat transfer rate due to the presence of the cast steel liner (the heat transfer rate of steel is 1/3 that of aluminum). Other problems with cast steel liner type cylinders are environment-friendliness and manufacturing efficiency.
On the other hand, there is an alternative type of cylinder used on high-performance motorcycles that replaces the cast steel liner with a layer of metal plating on the cylinder wall. This kind of “plated cylinder” has superior cooling performance (about 60% better than a cast steel liner type) but also has the problem of higher production cost.
And while the cast steel liner type cylinder and the plated cylinder have been used on different models based on their relative merits, the industry has been seeking next-generation mass-production technologies for cylinders that would stop the rise in production cost and enable the production of cylinders that are both environment-friendly and highly functional.
The Yamaha “DiASil Cylinder” is the product of a new technology that enables the low-cost mass production of an all-aluminum die-cast cylinder with excellent abrasion resistance, high production efficiency, excellent recycling potential and cooling performance equivalent to that of a plated cylinder.
Development background
Cast steel liner type aluminum cylinder
The detrimental qualities of a cast steel liner type aluminum cylinder include the more complex manufacturing process, heavier weight and poorer cooling performance.
Plated cylinder
Plated cylinders are presently used on high-performance motorcycles engines, but the production cost is higher.
DiASil Cylinder
An all-aluminum cylinder manufactured with the DiASil Cylinder technology has no need for a cast steel liner or cylinder plating, which means a simpler production process. What’s more, it has the same outstanding cooling performance as a plated cylinder.
In general, motorcycle engines run at high rpm (10,000 ~ 20,000 rpm) and the resulting highrunning temperature makes cooling performance very important. That is why lightweight aluminum, with its excellent heat transfer rate, is used for motorcycle cylinders. These cylinders made of inherently soft aluminum have a cylindrical cast steel liner inserted along the inner wall of the cylinder to reduce friction resulting from the piston’s movement. Thus they are called “cast steel liner aluminum cylinders.”
This construction, in which a cylindrical steel sleeve is inserted along the inner wall of the cylinder, produces a cylinder which is very reliable from the standpoint of reduced friction and reduced possibility of engine seizure. That is why Yamaha uses this kind of cylinder on approximately 70% of all the motorcycles it manufactures. In the case of models for the markets of Asia and Central and South America, this figure reaches about 90%.
However, there are also problems with the cast steel liner type aluminum cylinder, such as the complexity of the manufacturing process involved in inserting the steel sleeve, the poor recyclability of these cylinders and the limitations in heat transfer rate due to the presence of the cast steel liner (the heat transfer rate of steel is 1/3 that of aluminum). Other problems with cast steel liner type cylinders are environment-friendliness and manufacturing efficiency.
On the other hand, there is an alternative type of cylinder used on high-performance motorcycles that replaces the cast steel liner with a layer of metal plating on the cylinder wall. This kind of “plated cylinder” has superior cooling performance (about 60% better than a cast steel liner type) but also has the problem of higher production cost.
And while the cast steel liner type cylinder and the plated cylinder have been used on different models based on their relative merits, the industry has been seeking next-generation mass-production technologies for cylinders that would stop the rise in production cost and enable the production of cylinders that are both environment-friendly and highly functional.
The Yamaha “DiASil Cylinder” is the product of a new technology that enables the low-cost mass production of an all-aluminum die-cast cylinder with excellent abrasion resistance, high production efficiency, excellent recycling potential and cooling performance equivalent to that of a plated cylinder.
to summarize :
Summary of the technology and its possibilities
For a cylinder (inner wall) with high resistance to abrasion, an aluminum alloy with a high percentage of hard silicon particles is effective, and an alloy with a silicon content of 20% is considered to have the kind of abrasion resistance that is suitable as material for a piston. However, with conventional die casting methods, increasing the silicon content made it more difficult to cast parts with good contact-surface quality because of the increased occurrence of casting cavities created by pockets of gas (air) that form during the filling of the die and the solidification of the molten aluminum that decrease the strength of the final cast part.
In order to produce a cast cylinder with a highly abrasion-resistance surface quality, the Yamaha “DiASil Cylinder” uses an aluminum alloy with 20% silicon particles. To made a cylinder of this material that until now was considered difficult to die cast with, the Yamaha-exclusive “CF Aluminum Die-Cast Technology” was used, with precise control of the die casting conditions to meet the specific needs of this alloy.
In specific terms, (1) the degree of vacuum in the die, (2) the temperature of the die and (3) the speed with which the molten aluminum is injected into the die are all precisely controlled in order to produce cast metal that has a highly abrasion resistant crystallization character with an even distribution of hard silicon particles. This makes it possible to mass-produce high quality all-aluminum die-cast cylinders without cast cavities.
Because this new all-aluminum die-cast cylinder technology reduces production cost while also improving cylinder function, it is a technology that can contribute significantly to improving product function and cost competitiveness of motorcycles for the Asian market, where presently 90% of all motorcycles use cast steel liner type cylinders. It is also an manufacturing technology that can be applied to automobile and outboard motor engines.
Summary of the technology and its possibilities
For a cylinder (inner wall) with high resistance to abrasion, an aluminum alloy with a high percentage of hard silicon particles is effective, and an alloy with a silicon content of 20% is considered to have the kind of abrasion resistance that is suitable as material for a piston. However, with conventional die casting methods, increasing the silicon content made it more difficult to cast parts with good contact-surface quality because of the increased occurrence of casting cavities created by pockets of gas (air) that form during the filling of the die and the solidification of the molten aluminum that decrease the strength of the final cast part.
In order to produce a cast cylinder with a highly abrasion-resistance surface quality, the Yamaha “DiASil Cylinder” uses an aluminum alloy with 20% silicon particles. To made a cylinder of this material that until now was considered difficult to die cast with, the Yamaha-exclusive “CF Aluminum Die-Cast Technology” was used, with precise control of the die casting conditions to meet the specific needs of this alloy.
In specific terms, (1) the degree of vacuum in the die, (2) the temperature of the die and (3) the speed with which the molten aluminum is injected into the die are all precisely controlled in order to produce cast metal that has a highly abrasion resistant crystallization character with an even distribution of hard silicon particles. This makes it possible to mass-produce high quality all-aluminum die-cast cylinders without cast cavities.
Because this new all-aluminum die-cast cylinder technology reduces production cost while also improving cylinder function, it is a technology that can contribute significantly to improving product function and cost competitiveness of motorcycles for the Asian market, where presently 90% of all motorcycles use cast steel liner type cylinders. It is also an manufacturing technology that can be applied to automobile and outboard motor engines.
nice info bro..
will post a news about diasil
will post a news about diasil
my diasil piston/block is only the 150cc or the 57mm,but i have use it for 1 week,selling it for RM400.all trimming is done,just p/play.
the 60mm piston/block set is RM220. i have sold 28set the last one that i send is to Xproject,hope he have instal it and he can give u guys some review. for me hehehe the best (price-power-quality)piston/block set is still this 60mm set.
the 60mm piston/block set is RM220. i have sold 28set the last one that i send is to Xproject,hope he have instal it and he can give u guys some review. for me hehehe the best (price-power-quality)piston/block set is still this 60mm set.
x1-r
hi, guys
i'm riding a x1-r
and looking for more mods to boost performance....
so far, i have the following mods
nsr carb
redbull racing cdi
fast throttle
unknown aftermarket pipe from my mech
but the performance seems a little let down...
so i was thinking to go for big bore
the bike is intended for fast road use, not race use
so i'm looking for lasting mods
will the yamaha 150cc block be sufficient???
hi, guys
i'm riding a x1-r
and looking for more mods to boost performance....
so far, i have the following mods
nsr carb
redbull racing cdi
fast throttle
unknown aftermarket pipe from my mech
but the performance seems a little let down...
so i was thinking to go for big bore
the bike is intended for fast road use, not race use
so i'm looking for lasting mods
will the yamaha 150cc block be sufficient???
ok, here 's the tacho.. the lower digit is the engine temp.. upper digit is engine RPM.. adjustable to 1,2,4 cyls... installation is simple.. just connect the positive cable to main switch and the other cable to spark plug cable, coil around it.. and you're good to go.. the thermal sensor is plug and play..
about the cam change only..
i can say yes.. it would give quite power change..
cam is very vital to increase the volumetric efficiency of the engine..
but the real deal is after upgrade of the block, cam then followed by bigger carb and CDI..
about the cam change only..
i can say yes.. it would give quite power change..
cam is very vital to increase the volumetric efficiency of the engine..
but the real deal is after upgrade of the block, cam then followed by bigger carb and CDI..
ady_hnr007
New Member
so, if we use 150 cc cylinder, how about the main jet? what size of 150cc piston?