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Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Sun Nov 05, 2017 5:54 pm
by Sandblaster
Any time you put together a prototype you can expect to run into some issues...
This is a minor issue that will only effect you if you are using the TSR cases with the Panthera E-Start.
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 109.jpg (370.9 KiB) Viewed 7312 times
As you can see there is quite a gap between the cases and the starter housing.
The Panthera starter housing has a lip around the outside edge.
The lip goes most of the way around.
I suspect that it is there for alignment.
The issue is that part of the lip hits on the case.
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 110.jpg (199.9 KiB) Viewed 7312 times
So a little material has to removed from the starter housing lip area.
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 111.jpg (313.03 KiB) Viewed 7312 times
Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Sun Nov 05, 2017 5:56 pm
by Sandblaster
I've got the starter housing ready to machine... Except I put a piece of tape over the vent area that is not shown in this pic..
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 112.jpg (249.83 KiB) Viewed 7311 times
In this pic you can see the area of the Engine cases that is interfering with the starter housing.
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASES AND PANTHERA STARTER ISSUES 113.jpg (347.7 KiB) Viewed 7311 times
Here is what a stock case looks like in the same area.
As you can see it has much more recess in it then does the TSR cases do.
- 20171105_100553.jpg (178.28 KiB) Viewed 7304 times
Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Sun Nov 05, 2017 6:01 pm
by Sandblaster
Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Sun Nov 05, 2017 6:03 pm
by Sandblaster
If you decide to do this project yourself but you don't have a milling machine, You can use a drill press, hand grinder, porting tool, Dremel, or a hand file
Or, you could contact Sebastian before you buy a E-Start and ask him if he would be willing to machine that area off for you..
Here is what I used..
- 20171105_100449.jpg (469.27 KiB) Viewed 7305 times
Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Thu Nov 09, 2017 3:22 am
by Sandblaster
Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Sat Nov 11, 2017 5:52 pm
by Markee757
Wild work!
Where you getting your hardware?
Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Sat Nov 11, 2017 11:07 pm
by Sandblaster
The engine cases TSR products Australia
The 2 piece clutch cover I made.
The Electric Starter is from Panthera in canada
The titanium fasteners are from all over the world but mostly China, US, and the UK
Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Tue Nov 14, 2017 11:22 pm
by Sandblaster
It's time for some changes...
First step... Get rid of the ridge around the kick lever shaft output area.
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 124.jpg (385.47 KiB) Viewed 7269 times
Next thing is to get rid of the splash guard for the filler plug..
Cut number 1.
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 125.jpg (516.78 KiB) Viewed 7269 times
Cut number 2
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 126.jpg (404.21 KiB) Viewed 7268 times
A little mill/drill work..
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 128.jpg (366.51 KiB) Viewed 7269 times
Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Thu Nov 16, 2017 3:43 pm
by Sandblaster
(In your best Arnold Schwarzenegger voice) unprogrammed mimetic polyalloy... liquid metal...
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 130.jpg (454.49 KiB) Viewed 7262 times
I have never tried this product... We'll see how it works..
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 129.jpg (156.38 KiB) Viewed 7262 times
Re: KX GURU Racing kx500 Engine in a 2016 KTM 250 SX PUMPKIN SEEDS BUILD
Posted: Thu Nov 16, 2017 3:47 pm
by Sandblaster
After prepping the cover I taped the back side to keep the material in place..
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 131.jpg (180.25 KiB) Viewed 7320 times
Because it Oregon... and it's cold and raining outside, I used the over to keep the temps up...
After applying the filler I let it sit for about 5 minutes then pulled the tape off...
Then I put it in the oven but left the door wide open to keep from over heating it.
My oven only goes down to 170f and that may be a bit warm
- KX GURU RACING TSR BUILT BILLET KX500 ENGINE CASE with a 2 piece clutch cover 132.jpg (204.46 KiB) Viewed 7320 times