Highfive - WRR Athena Big Bore Project

Discussion in 'Thumpers' started by HighFive, Sep 18, 2010.

  1. 10Cup

    10Cup Long timer

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    Hi HF, I know you mentioned mileage some time back but would be interesting to know what your range is now when you get a feel for it.

    Thanks
  2. HighFive

    HighFive Never Tap-Out

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    Hey there....10Cup! Long time, no :ear. Trust your WRR is still kickin. How many miles you got on it now...40k?

    I spent today flogging R² around the rocky, hilly trails of Camp Gruber ORV, near Muskogee, OK. I blasted down the Superslab at 75 mph non-stop for nearly an hour to get there. Then, it was off into the forest for a few hours of serious trail riding. Raced two guys on the enduro loop for a good while (KTM & KX). Worked it hard to the rev limiter in 1st & 2nd gear quite a bit. Lots of on & off the throttle. Then, I did some county road exploring for a long lazy ride home over the next couple hours....averaging 35 - 65 mph. Covered the full performance range across various conditions while burning a full tank of gas. I took no baby wipes, nor spared her any mercy. :deal

    The bike ran spectacular! And, she drank the go-juice at a rate of 53 mpg. :freaky So, I've still got a 200+ mile range with my Safari tank....no worries.

    I'll keep tracking fuel mileage over my next few tanks to verify. But things are looking PDG (purdy darn good....for all you yankees).

    HF :thumbup
  3. HighFive

    HighFive Never Tap-Out

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    .....guess I should mention that 53 mpg was on Real Gas, not ethanol blend.

    HF :thumbup
  4. 10Cup

    10Cup Long timer

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    Awesome HF, great job!
  5. tompee

    tompee Adventurer

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    Again, great feedback to hear about the kit. Very interested in all this information
  6. MrGoldfish

    MrGoldfish Been here awhile

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    This has been quite a cool thread to read. I'm glad I got to drop in on it and read it after the fact instead of having to wait since 2010 (if I remember correctly) when HF started work on it. Awesome job HF!

    I grew up riding XR's around Arizona and now that I'm almost graduated at ASU I'm dreaming about getting a dual sport that I can slab to the trail with. But, I still want a bike that feels light and nimble and "can go anywhere" as the general consensus of the WRR community seems to agree on. I think this bike would be even better than I thought with a 290 kit on it as well.

    Finally, I must give credit to HF and all of his cronies as well as Big Dog who have given me reason to drool over the WRR. What a sweet ride! :clap
  7. DR Rider

    DR Rider n00b

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    Fantastic thread! Great information. I've never been much of a mechanic, so I learned tons here. Someday I might even get up the courage to try it myself.
  8. Just Bob

    Just Bob Been There Done That

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    Thank you HF for keeping me up way past my bedtime. Very good stuff! :thumb:thumb
  9. Just Paul

    Just Paul Pro Cat Herder

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    thanks for keeping me up past my bedtime also !

    great read :clap
  10. Tessier

    Tessier Been here awhile

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    I thought about doing this same upgrade to my WR but when I looked at the numbers and really thought about it selling my WR and putting my money towards a TE310 made a hole lot more sense. Now I couldn't be happier.
  11. thumpididump

    thumpididump MacGyver

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    I'm confused... did you spend the money and do the upgrade, and now you couldn't be happier?? Or, did you buy a Husky and now you couldn't be happier??


  12. Strog

    Strog Geek on two wheels

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    His other post is signing into the TE310 owners thread about scoring a leftover '11. :deal
  13. madmac333

    madmac333 Adventurer

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    Great work HF! Thank you for this thread and the high level of detailed photos and explanations. I'm on the fence about the WRR. Knowing its potential (and what it takes to realize said potential) is a HUGE help. :D
  14. HighFive

    HighFive Never Tap-Out

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    Your welcome, Madmac. It was a fun project...albeit a long one. I'm still enjoying my WRR. Its a great bike even in stock form. You don't have to swap to a big bore to seriously enjoy the bike. It will happily, comfortably, and effectively explore highways & byways, backroads & country lanes, two-track & single trails with the stock motor.

    The stock WRR will easily go faster than any posted speed limit, carry the mail, and haul the water! :deal

    If you really want a superior "woods racer", then buy one made for specifically for that. This pony is truly dual-purpose, and a beautiful compromise at that.

    HF :thumbup
  15. Crawdaddy

    Crawdaddy Navigate 2 Adventure

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    Is the Athena jug a std cylinder with a bigger bore (and therefore thinner wall more prone to over heating) or is it a stand alone cylinder of comparable wall thickness?
  16. athletejmv

    athletejmv n00b

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    HF, I just wanted to give my thanks for your thorough posting on your Athena big bore kit installation. Everything was straight forward and the directions you provided were great. Resetting the hydraulic for the timing can also be done by hand by applying pressure and twisting it clockwise. I did this on the pavement over a rag to keep from damaging the surface. Once more thank you very much ! ! !
  17. HighFive

    HighFive Never Tap-Out

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    Oops...didn't notice your post for awhile. Guess I should subscribe to my own Thread...eh? :lol3

    I think its a stand-alone unit, as you say. I believe Athena makes their cylinder from scratch, not simply boring an OEM out. I say that, because the Athena name is in the casting. I did not compare wall thickness between the two. So, I couldn't say for certain how that compares.

    I've not experienced any overheating issues to speak of.....and spared it no mercy when riding (as usual). I've never made any surface temperature measurements of either cylinder in operation. Frankly, never cared about it myself. I don't ponder, wonder, or even think about it anymore.....I just ride it. She's been running great every since I finished with this project. No problems, no worries, for me.

    I will admit my Husaberg affair has been interfering with my R² relationship a little bit. :lol3 So, she's not seen as many miles as she might have otherwise. But so far, all's well.

    HF :thumbup

    p.s. if I had it to do all over again, I would have bought the Husaberg sooner, and left the WRR stock. :evil
    For the money.....just sayin. Not meaning to discount my modified WRR any. She's a real fine ride indeed, especially now: Mobile, Agile, & Hostile! She came with the first two characteristics. I have added the third. The extra pulling torque is very nice to have.
  18. HighFive

    HighFive Never Tap-Out

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    Your welcome! Glad you enjoyed and found it inspiring. Thanks for the feedback.

    HF :thumbup
  19. Crawdaddy

    Crawdaddy Navigate 2 Adventure

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    It's my understanding I need to move away from my FMF Programmer and over to a Power Commander V to account for the larger cylinder........was that your motivation to jump from FMF to the Power Commander?

    There's a mapping specifically set up for the WR"290"R (22-043-11):
    http://www.powercommander.com/power...del-n=WR250X/R&year=2008&mk=28&mdl=96&yr=2008

    My bike has the Dr "D" (Dubach) exhaust, FMF Power bomb header, open flap, stock air filter.......I can't imagine that there's much of a difference between that and the full FMF system mapping with flap open/stock filter (map 11)
  20. HighFive

    HighFive Never Tap-Out

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    No, that is not why I moved to the Power Commander from the FMF unit....per se. When I rode the Highfive Cascade Tour, I was very impressed with the fuel metering on Cyborg's stock WRR with a PC-3. You can read about that in the link provided.

    It had been dyno tuned and was spot on perfect, super smooth off bottom. That is the moment I was sold on the Power Commander. It has so much more control capability than the very limited FMF unit. Consequently, its more expensive for good reason. When I departed Seattle, I knew I would make the switch. I would have done so, even if I was running the stock motor and not doing this Athena Big Bore mod.

    I went with the PC-5 because I wanted to add the Auto-tune unit to my WRR and make it a "closed-loop" system. This is an option...not a requirement. The A/T has a wide band O2 sensor for the exhaust pipe. The whole system works very well. Taking it to the dyno, I developed a personalized set of fuel maps, specific to this particular motor and setup, with incremental fuel adjustments at every 250 rpm, and 5% throttle opening. And, made one of those complex, unique curves separately for every single gear.......all based on HP & Torque optimization thru the rear wheel (turning the dyno drum). Very cool. :evil

    I can flip the A/T on or off at my pleasure. I usually keep it off for trail riding, and will often flip it on when running the roads. The motor runs better in stop & go tight trails with a constant fuel curve. The A/T will constantly adjust fuel metering to hit a consistent AFR ratio loaded into the table. Its a better application for a more steady state operation, not constantly changing throttle a load inputs. Though, it functions extremely fast....maybe faster than the ECU can deliver the commands. These are just impressions I've formed in the saddle since completing the project. I could ride it either way at any time with no problem. You learn your bike and how it feels....its all I'm saying.

    I am totally 100% impressed with the Power Commander product. It is in a whole different category than the FMF unit. If you want to eliminate the snatchy, jerky low speed throttle of the stock WRR.......simply get a PC-3 or 5 and try some of the available curves. Better yet, have your bike dyno tuned specifically for what you want.

    It is important to note, that I was an early adopter of this system on the bike. As such, there were not very many fuel curves available from Power Commander...maybe 3 or 4...and none for the 290. I tried each one at first, and was not satisfied with any of them. Dyno Tuning was much more effective and gave me a curve to my bike AND what I specifically wanted. More curves are available from PC now. Might work for you....might not. I donno. Try it and see. Personally, I've never regretted a dyno tune. It let's me sleep real good at night!

    HF :thumbup