Crofter985'S KLX650C supermoto build

[Sandblaster]

Wow!
I've been busy and I see you have been as well.
More info on this later...

[Sandblaster]

Wow again!
That is looking great.
Yes, it seems that a lot of bike have problems with the crank.
I know that kx500's have a crank issue when running past 10k or so.
On my last crank build I used a Wossner and had the assembly welded, balanced, and trued.
We did a direct comparison of OEM, Wossner, and IMS Pro.
The Wossner appears to be the best built.
I wonder if they have a Wossner for your 650?

[Crofter985]

I have a Wossner piston, I bought it 2nd hand but it's unused. It is a few grammes lighter than the stock, I'm not sure if that's 100% a good thing.
I am in touch with a guy who has a complete low miles KLX 650c motor, I am going to talk with him today. I have a plan in mind to build a motor to replace the one in the bike. I found a place in California called webcam who produce a few cam profiles for the klx.
If I could boost the bhp of the original motor, the extra bhp potential of the inlet pressure with the turbo should be greater too.
This is crank hell I would imagine, I was always led to believe Kawasaki had strong bottom ends so we will see.

[Sandblaster]

After comparing all the different pistons for KX500's I also use a Wossner.
They seem to have the highest quality and will definitely stand up to high loads.
If I wasn't going to use a Wossner I would use a OEM.
For some reason Wiseco's have dropped their quality a bit...

[Crofter985]

Got some more done on the exhaust. I've put a expansion joint in at the top just before the exhaust turns downward again, it's just the pipe turned down a mm and the next part before the downhill bend bored out a mm over 20mm of the pipe length. I will fit springs to it after I clean it up with the grinder.

That's it with the exhaust for now. I can't do any more till the silencer arrives and I can fit the rest of the exhaust to it. Next job is to get on with the subframe.
But, a couple of the lads I work with came over so it was time to fire the beast up for a bit of fun!!!!
http://youtu.be/sVbTMkW-Ms0

[Sandblaster]

That's great!
I can't wait to see what that thing does out on the road

[Crofter985]

Got this in the post today, it's the CDI unit from ignitech.cz , looks like the right stuff. The CDI unit is there, a MAP sensor at the bottom of the picture, a serial connector and a serial USB connector, the software on the cd, also the appropriate connectors so it clicks straight into the existing loom.
This sort of complication is something that I thought I wanted to avoid but as I progress with the build it seems more appropriate. Techno fear will soon be a thing of the past! 262 euros for this btw.

[Sandblaster]

So.... after a full weekend of having that set up in your possession is it running?

[Crofter985]

Ha ha, sorry no. I was only home overnight, I opened my mail and went away back to work. I work at sea, you see. but I'm going to hang up my spurs for the holidays by the 23rd.
Startup proper is still a little bit off, the plenum is to finish, the exhaust to finish and the wiring.
The plenum/subframe is complicated by so many things, wiring, w/m injection plumbing, battery installation/cable routing.
The exhaust is reasonably straightforward, the silencer has arrived, there is pipe and bends ready to go and the bung for the A/F sensor.
Wiring? Well it's not too much. The new CDI might still be in the box for the first startup with the intake completed. I'll put the MAP sensor in but it won't be connected to anything.
Oh and the tank, the tank needs this fuel pump welded into it. So there's a bit to go.
Even the fuel tank needs power now!

[Sandblaster]

Ah..... You work at sea.... Chief Engineer?
Your thought and detail process have been outstanding.
I've seen a lot of different builds but this is one of the more special builds.
Thanks so much for posting...