Crofter985'S KLX650C supermoto build

[Sandblaster]

I sure enjoy watching you fab stuff and go for it...
It's how we learn

[Crofter985]

My wife is away on holiday so I took the opportunity to put a few engine parts trough the dishwasher. I had already boiled the cylinder head in a pot for a day in water with a few dishwasher tablets in as well. The exhaust ports was the worst bits, boiling them softened the carbon deposits and the cycle through the dishwasher flushed it all out.


I polished up the valves and lapped them in and lapped the head and barrel together before the trip to the dishwasher.

[Sandblaster]

Looks good.
Too bad you weren't a bit closer, I'd run your parts through the vapor blaster for that extra special look
Just curious, what did you use to lap the cylinder to the head?

[Crofter985]

I know, the cases could really do with a shine up. But it's just cosmetic, eh? I just need to get this damned thing going.
It was just valve grinding paste.

[Crofter985]

This is the original bike engine, I am going to use this as the base for the first motor. It's cases are the best. There is a filter screen in between the cases, I really need to look at it, the other screen filter in the engine was quite gummed up so there's a good chance it will be too.
It wasn't too bad. With the cases split I might as well have a go at the crank too.

WTF! I used more heat, got more pressure on it then it went witha bang, the same thing again, lip broke off the crank.
Well, ongoing to carry on building the motor so the Carrillo rod is going to have to sit on the sidelines. I'm gutted but it will go in later.

So I put the first crank I tried pressing apart in (because it was cool) and wossner piston in and got the barrel on. I honed that yesterday before it went in the dishwasher. Now I forgot to get a torque wrench, so I'm going to leave it at that tonight. One more thing I did as iwent along, I drilled out a little plug in the oil ways going to the gearbox the reason being I want to create a test point for a oil pressure reading. I drilled it out to 6.5mm then ran a m8x1.25 tap in it. Then I milled a flat on to the area so I would get a good seal.

So that's the progress for now. But one last pic, this was the sight when I took the head off this motor, I don't think this head joint could have been sealing properly so it's a good job I didn't just slap the turbo on and go for it.

[Sandblaster]

Nice job with the oil pump pressure fitting.
I was wondering how you might do that.

When you are lapping aluminum, see if you can find some Timesaver..

viewtopic.php?f=39&t=421

It will not impregnate into the surface aluminum.
This stuff is amazing...

[Crofter985]

I'll have to get some of that stuff.

[Crofter985]

I got a bit more done with building the motor.



So that's the head on and torqued down, valve clearances done, cam timing, generator and starter gears on and cover on. I've just put the exhaust on (straightened out to direct the noise away from the engine while I'm running it in/testing the oil pumps. So that's the starting point, I'll just get it running in standard form, near enough. I'm not too far off with my dyno now, I intend to run this up on the dyno with no turbo first to see what the power is like with the engine as it is and the fcr 41 on it.

[Sandblaster]

How far along are you on your dyno?

[Crofter985]

I ordered the interface box at the weekend. And the roller is being worked with but I'm not sure how far on it is, the guy said though when he started it he would have to finish it. The chassis, well I have been collecting some big heavy H beams to make a chassis, 14"x12" beams, heavy to help damp out any small amount of vibration.
i don't really want to start the chassis before I get the roller finished and get it there in front of me.
Just have 6 days off left.