Crofter985'S KLX650C supermoto build

[Sandblaster]

5 days left

[Crofter985]

Only 4 tomoro

[Sandblaster]

You just have to do what you can while you are home and dream about it while you are away

[Crofter985]

I got the motor all together today with the standard oil pump, hooked the engine up to the harness and got it running. Just at idle, new piston and all.
I made up three adaptors for testing the oil pressure, mounted gauges to the filter cap, the cylinder head and the gearbox feed.

The gauges are all in that pic. With the standard pump I was getting about 13-15 psi at the filter cover at idle, I can't remember what the reading at the cylinder head was but the gearbox was only giving a reading if I revved the engine to 3000 rpm??? That's not a lot of lube to the gearbox. Well I'm not going to think about it too much, It's standard set up. If anyone reading this has read the whole thread you may remember I did a test on this bottom end, it had a different top end then, the pressure was up to 25psi but I think that was with some revs, how much I couldn't honestly say.
What this makes me think is there was some restriction before that is not now, this could be explained by what I saw in this engine, the exhaust cam was a bit scorched looking and the exhaust cam bearing surfaces of the head were a bit poor, they looked like they were about to pick up.
The oil is fed to the cams from the inlet side first so there might have been less flow and pressure at the exhaust side??? Anyhoo, it was 13-15psi today.....
Then I put on the uprated oil pump, ........... Well it started off at around 28-30, I sh!t you not, although as the test went on the pressure fell back eventually to just the better side of 20psi, the oil would have been heating up or the pump could have been made by a self trained hack machinist and be shredding itself merrily. Well that's all to find out tomorro.
I think it's proof of concept, even if there is a problem with the making of the pump, I think I will get over any of the hurdles from now on. Confident Eh? Well we will see.
http://youtu.be/_tTNmyiQ_cc

[Crofter985]

Couple of pressure test pics here.


22psi at a slow idle. Should be a lot at higher revs. I need to run a bigger bore pipe to the turbo so I don't get pressure drop over the pipe run then bleed exsess oil from there to a oil cooler.

[Crofter985]

The frame was shot blasted a month or more ago, then I primered it but as there was a couple of little bits of welding to do it was left at that.

When I started the subframe/plenum I made the brackets and the aluminium parts that join the subframe to the frame with 6mm bolts, right away when I started building up the subframe the bolts became a pain in the hole to get in and out, the aluminium of the subframe pulls so much. The idea with 6mm bolts was so when I got to this stage I would drill out the holes one at a time to 8mm and fit captive nuts to make mounting and dismounting the subframe a bit easier. So that's what I've done today. Also when I was fitting the carb to plenum pipe I had to grind away a bit of the frame so today I've also plated that over and tidied up and primered it.


Now I've got to make it black.

[Crofter985]

There it is, two tins of spray paint later. I did buy a couple of really cheap spray guns off the internet but my compressor disabled itself the other day so rattle cans was the only way.

Now, it's saturday, wife is away, let's go.... BEEEEER!!!

[Crofter985]

I left the frame overnight to harden the paint. Then put the engine in. That engine is heavy BTW.

Then I put the swing arm and wheel back on, hampered by the fact o couldn't find the lower shock mount bolt, it has a half height nut too so this was a nuisance, but I found a bolt and nut that was about 5mm too long, so I milled the bolt and nut together to the correct length.

This is the shocker I got for it a few weeks ago, it's a YSS it's made in Thailand, it seems to get good reviews in tests.

That swing arm looks pretty yuck, I will paint it later.

[Crofter985]

A bit more like a bike.

I've put this together because I have to make and make fit an adaptor between the carb and the head. It's a good boost to see it looking like a bike again.

It rolls, it's not done that since this time last year.

I welded paddock stand bobbins to the swing arm.

I welded that weeks ago and also the new shock was ordered months ago, it was not in stock in this country but I was glad it was even made for this model of bike, aftermarket stuff is not so easy to get. But check this out!!! The shocker spring is a bigger diameter than the old one, I would say there is 1 but not 2mm clearance. Lucky!

When I put the subframe on first I thought it touched, I took it to the bench to cut it up, but thought I would double check, good job I did.

[Sandblaster]

Wow!
I would call the oil pressure tests a success.
Not being a professional tester I have many times not seen the end from the beginning and failed to record the right info.
But I think you nailed it pretty good.
I might have missed it but what was your pressure in the gear box with the new pump?

And, it's looking good!!!