Author Topic: klx450/kx500  (Read 87572 times)

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Offline ylwgtr

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Re: klx450/kx500
« Reply #75 on: November 17, 2013, 10:21:53 PM »
weighed all the parts today....it all weighs 1.7kg for the weight concious guys.....im happy to put up with it myself
« Last Edit: November 22, 2013, 07:12:05 PM by ylwgtr »

Offline ylwgtr

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Re: klx450/kx500
« Reply #76 on: November 22, 2013, 06:44:46 PM »
case machined to receive rebate
 

Offline ylwgtr

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Re: klx450/kx500
« Reply #77 on: November 22, 2013, 06:48:50 PM »
had to weld the 3 odd mm air gap left from the old wire grommet

Offline ylwgtr

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Re: klx450/kx500
« Reply #78 on: November 22, 2013, 06:49:47 PM »
plate mounted on


Offline ylwgtr

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Re: klx450/kx500
« Reply #79 on: November 22, 2013, 06:51:30 PM »
finished minus flywheel mods


Offline ylwgtr

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Re: klx450/kx500
« Reply #80 on: November 22, 2013, 07:17:05 PM »
this old girl gave up its life today in honour of electric start r&d.....it was a shagged crank i had lying around out of my 87 kxt250 tecate....the seal area was rusty .....im using the shaft to machine the flywheel hub on so it stays as true as posible.....2 mins of silence for the poor old girl please


Offline ylwgtr

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Re: klx450/kx500
« Reply #81 on: November 22, 2013, 07:20:57 PM »
the old KX500 flywheel also copped it ....ive removed the hub and machined off the flange

Offline ylwgtr

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Re: klx450/kx500
« Reply #82 on: November 22, 2013, 07:23:51 PM »
im going to bore this bad boy out next....i will machine the hub down with a stopper step on it and bore the flywheel to receive the hub,put a nut and a bolt in the centre to hold it put while i drive the TIG over it

Offline Twosmokerfan

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Re: klx450/kx500
« Reply #83 on: November 22, 2013, 09:22:14 PM »
Hey mate. I so look forward to your updates! Round of applause to you for the level of commitment you have shown. I can't wait to hear about the first test and how it goes when you press the button.

Love your work!
TSF

Offline alward25

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Re: klx450/kx500
« Reply #84 on: November 23, 2013, 01:23:45 AM »
How did the taper compare?  How hard would it have been to rework the taper to match the KX 500?  I don't have a ktm flywheel to compare.  Keep up the great work!
"Let there be light"

Offline ylwgtr

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Re: klx450/kx500
« Reply #85 on: November 23, 2013, 11:20:28 AM »
Thanks TSF....alward the taper on the KTM is very steep at the rear of the flywheel then changes angle....even if you could get the flywheel to direct fit without any type of hub mod it would still need to be packed out the correct distance to allow the bendix drive to make contact with the ring gear....therefore needing a hub mod anyway ...hope that makes sense

Offline ylwgtr

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Re: klx450/kx500
« Reply #86 on: November 23, 2013, 11:22:29 AM »
you can see the first angle on this pic


Offline ylwgtr

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Re: klx450/kx500
« Reply #87 on: November 23, 2013, 11:25:35 AM »
can also be seen on the ktm crank...unfortunatly no easy way out here.....lining the KX500 hub,ktm flywheel (with crank angle ref tab) and the engine  relative to ? degrees to TDC is going to be fun as the pulse pickup is bolted to the engine cover....I will need to get my mates ktm300 back and find out what degrees before TDC the leading edge of the ref tab passes the sensor (which i will have to make a mark on the crank case itself as mentioned you cant actually see its position when youve removed the cover)



« Last Edit: November 23, 2013, 11:35:58 AM by ylwgtr »

Offline ylwgtr

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Re: klx450/kx500
« Reply #88 on: November 24, 2013, 11:15:03 PM »
Ok...back into old mates ktm300...the pick up see's the leading edge of the ref tab at 30 degrees BTDC and the trailing edge is TDC.....what generally happens here is during crank/kick starting the CDI will read from the trailing edge and once running it will read from the leading edge....the trailing edge turns out to be located directly in the center of the wiring grommet which makes my job easy...so I will park the kx engine at TDC line up the tab with the grommet hole and put the ktm flywheel on the kx hub


Motorrad

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Re: klx450/kx500
« Reply #89 on: November 25, 2013, 12:45:43 AM »
Doesnt get much easyer than that