klx450/kx500

[ylwgtr]

weighed all the parts today....it all weighs 1.7kg for the weight concious guys.....im happy to put up with it myself

[ylwgtr]

case machined to receive rebate
 

[ylwgtr]

had to weld the 3 odd mm air gap left from the old wire grommet

[ylwgtr]

plate mounted on

[ylwgtr]

finished minus flywheel mods

[ylwgtr]

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

[ylwgtr]

the old KX500 flywheel also copped it ....ive removed the hub and machined off the flange

[ylwgtr]

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

[Twosmokerfan]

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

[alward25]

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!

[ylwgtr]

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

[ylwgtr]

you can see the first angle on this pic

[ylwgtr]

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)

[ylwgtr]

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]

Doesnt get much easyer than that