Motorrads Jeff Ward engine build series 2

[Sandblaster]

Here is a interesting little thing...

All my NEW Kips levers showed up today. (due to mine being bent, and worn) angry

And noticed this..

The NEW arm is longer than my old arm.. (2.54mm center to center) to be exact...

I havnt assembled it all to see what this is going to do on the bike yet... figured I share.. incase one of you knows why, and can tell me before I mock it all up to see what it does..

Motorrads Jeff Wards Engine build round 2 8-1.jpg (175.33 KiB) Viewed 7577 times

And incase some are confused as to what the lever in the case is supposed to look like angry
It is not supposed to be bent.. (I have talked to guys, that since every single one they have seen is bent, they think it is supposed to be that way...)
Make your kips work properly boys and girls..

And vice gripped hardware just bothers me, so it got replaced....

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[Sandblaster]

Havnt dug into part numbers yet.. Beyond both arms are differant from my 91 to the newer... the govener arm is superseeded by the new number... and the arm we are looking at now is just straight listed as "disscontinued" But here are some pictures of mock up..

Old.

(IN)

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Motorrads Jeff Wards Engine build round 2 8-8.jpg (100 KiB) Viewed 7577 times

(OUT)

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[Sandblaster]

NEW

IN

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Motorrads Jeff Wards Engine build round 2 9-2.jpg (87.54 KiB) Viewed 7577 times

OUT

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Measurements

(the spacing from Center of hole and pin is same to outside on each.. so just measured this way for easy picture)

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[Sandblaster]

Since I dont have a stock Kips Bolt around here... can you give me the measurement differance between stock and modded. (how much further out it pushes the actuating rod)..

Im gonig to take my actuating rod out, and cut a new E-clip groove in it. to locate the arm further in for better angles.... as it sits now, when it starts to get to full travel, you can tell the arm is fighting to slide in the (ring) as its starting to want to travel downward too much...

from my quick math.. if I move the E-clip in .2305 the lever will have equal distance of travel each direction from mid stroke..

You guys are too slow...

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Motorrads Jeff Wards Engine build round 2 9-8.jpg (76.28 KiB) Viewed 7577 times

[Sandblaster]

Here.. much better..
Full close/full open

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[Sandblaster]

alward25:
.383" and .538 I had some time and some dial calipers. That is without a crush washer.

Motorrad:
Thank you sir...

That tells me that I moved it all in farther than stock ever was... Interesting..


Okay. so I was thinking this long vs short arm thing through today..

I think Im going to run the shorter arm...

Here is why..

I think the reason they went to the longer arm is to deal with the ammount of travel the kips had.

With the kips bolt mod, we take alot of travel out of it... and with me cutting new grooves, it gets the angles better...

The Longer arm will cause MORE stress on the kips govener arm, (the one that likes to bend).. as the longer arm will reduce leverage.. ..

[Sandblaster]

Larry Wiechman:
Untill you add another dowel pin to positively locate the head, you're wasting your time trying to establish an even, concentric squish gap.
Look carefully at a stock Kawasaki head gasket.
See the provision for the second dowel?

DoldGuy:
Larry,
Are you saying the head has enough movement around the studs to change squish from side to side, or front to back & the additional pin would positively locate the head? I don't have a stock Kawi gasket to look at, does it have a hole for another pin? Up front?

Larry Wiechman:
Yes, the stock KX500 gasket has a hole for a dowel pin at the front of the cylinder. It's not a big issue with a relatively flat top piston like a 500, but in the motors with domed pistons, it's defiantly something to be aware of.

Motorrad:
Well . I went out and stared at it for 20min... (Warning.. Im a case of beer in on the evening)

only thing I can come up with...

IS..


Idiots trying to pound cases on, when everything isn't lined up properly. (or seated)... (govener installed into center cases, instead of in outer case durring assembly)

Its the only way I can see the lever getting bent in the direction it is bent in..

and the "Idiot marks" on my bent lever are in perfect alignment with this theory.

[Sandblaster]

Well since Im at a standstill waiting for Custom base gaskets (thank you alex), Piston rings, and head work..

I made the motor look like a "motor" from the outside... yes its just a lower end with a empty jug and head on it....

To treck down to my Local DMV and see if I can Lie my way into turning my AZ plate into a CA plate...

Looks street legal to me with no expansion chamber on it Wink

Yes the Promoto kickstand is a 2x4 away from working with supermoto tires.

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Mrs Motorrad (Allyn) and Baby Motorrad (Eryn)

[Sandblaster]

Okay.. Got some stuff done..

Got me a package from cometic (via Alward25.. thanks alex..)...
Lots and lots of port duration/time, squish.. experimentation options, as they all are dif thickness's... AND notice the kips holes are now smaller Wink thanks for that tip Doug...
My head hurts already..

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[Sandblaster]

Okay... since I am getting tons of questions regarding the shims I used on the KIPS via PM...

They dont quite fit right... the hole in the center is a bit big... so it can walk around... Im not using them perminant... I used them to mock up and figure out how far out I am... By placing them between the cases and the jug like it was part of the base gasket (not above the kips guides)...

I am going to machine new alum kips guides to the correct size...

If you wanted Im sure there are shims out there the correct size if you looked hard enough...

These are from the RC car industry (yokomo to be exact)..